First Project - Trampoline Poles

[Johnny55]

I just got my new welder (161STH) and had a my first potential job. Earlier this winter, my kids trampoline became a kite and bent or snapped 4 of the poles that hold the netting around the top. I looked at just buying some new legs and realized I may as well buy a new trampoline for what they wanted. I was able to straighten some of them out just putting them into the press, but had two that were extremely mangled right where the round tube is formed down to a square to slide into the trampoline. It is some odd sided galvanized pipe. Please keep in mind I have zero fabricating experience let alone welding, so I am sure there was a MUCH better way to do this job.

Long story short, I bought some 1/2" flat stock and attempted to use it to fuse around all of the rips and dents. I have no gas so this was done with the stick welder. 6011, 40amps, hint of hot start and 60% arc force. I tried 6013 but it wasn't working as good on DCEP. After watching some youtube videos from weld.com and weldingtipsandtricks, I tried DCEN which laid down more material but didn't seem to fuse the metal at my settings. I stuck with the 6011 after a bit of fiddling around. I realized that this was not the best process here after the first time I lit up and saw it blow through the pipe instantly. I practiced a bit until I could do it with minimal issues and then welded the two legs back together. The tear was directly where the pipe had been formed into a square that slides down into the trampoline so I didn't see how I could cut out any bad spots. I basically filled in the craters, tears and built up around the flat stock. They look horrendous, but they are back together and I didn't spend 160$ for new poles. Now for a light coat of paint and reinstall them on the back side of the trampoline so no one has to see them.

[performance]

It's probably galvanized, and welding it will also make you sick from metal fume fever.

[Johnny55]

I did take a flap disc and get the area down to bare metal first. So far so good. I know that the fumes from this stuff were made out to be a pretty serious deal from the one day course I took so I also did it with a good respirator on. The trampoline is 100% back together and bounce tested and my patch to the jumping mat is also holding.

[performance]

Flap disks are no good for this. They tend to polish more than remove metal. Use hard stones only.