[QUOTE=ironworks;331984]Roger is that a cut a tight fit or is that a slight gap? If its a gap are you using a filler rod?

Mario --

The "pros" might offer a different opinion - but a "gap" is a burn through for me. I can jump the gap (I weld far more than the average guy but nowhere near what a pro does) but it's far more work and makes it far harder to weld.

Do not listen to the instructions on the tungsten stick out rules (3 x's the dia)...
If I can't SEE the tungsten I can't weld... so I run a bit more stickout (I also run a gas lens so gas flow is better - to cool the tungsten).

The fill is a coordination 'dance' for me - I move my torch forward which pushes the puddle forward and then I bring it back just a schoosh and as I do that I dip the fill then advance that (pushing it forward) and so on. I'm an old school gas welder - where you made circles with the torch and dipped the fill when the circle was 180* at the back of the circle (does that make sense). And I've tried that technique with my TIG torch but found it to not be necessary.

Do you have a foot control? I light it up - get the puddle started and immediately back off - dip - push forward - move back - dip - forward - and always watching the puddle and using the foot control to add or subtract heat as needed. I always "coast" up to the end of a weld - dipping a couple times to finish (eliminates the crater).

Also -- do you have the torch angled back - I'm probably at 30 to 45*. You can't angle back as much if your stick out isn't right... and the heat goes up as the gap of the arc lengthens (that might not be technically correct - but it's what I see). I keep the arc pretty tight - so on thin gauge sheet metal - the arc length is probably only a 1/8th inch maybe less.

Don't give up -- TIG is the best welding a guy can do.... the clean up is far less (easier) and the control is by far the best.

Thanx Greg!! I'm commited to make this work I never give up ... But it is frustrating let me tell you . I'll bring my tungsten out a little more,and I just ordered the glass lens for the tig tourch. I do think vision is a big part of my problem. Its a little harder for me I have no vision in my right eye. I hope the new helmet works better than my Miller.. I looked at Rogers picture and I figured that it was a gap . Man thats some crazy control to be able to fill that gap..

Well..... there's always going to be a gap... But I like my gap less than the width of my fill rod...

I have a couple of torches -- and prefer my smaller "2 series" torch it's lighter and has a super flexible hose. The torch that came with my machine doesn't get used unless I'm doing something larger. I use a 1/16th tungsten... and 1/16th fill rod on sheet metal.

Torch size is important... :D

Mario trust me you are going to LOVE LOVE LOVE that Optrel helmet. I just got mine the other day and MAN what a difference. I have used other highish end helmets and they do not even come close to the optics of the Optrel.

Greg is giving you great advice. I would add maybe try a thicker material until you are comfortable with the torch, filler and pedal control. Just some food for thought but hey I started with Aluminum so my opinion might not be the "norm". Actually I have an easier time with aluminum than steel but I have been practicing steel more lately so I can hold my own there now too.

Chris

Exactly what I have always said too! When I first started to TIG everyone said the same deal 3x diameter should be the stickout finally I started experimenting on my own and found MUCH better control with additional stickout.

i didnt listen and picked up the finger controls for my dynasty. huge disaster. trying to keep your hand stable while rolling the trigger doesnt work. i need to pick up the foot control and give it another shot. luckily for my exhaust i was able to do a fusion weld. it made controlling the hand controls much easier.

a couple things that i will echo; sight is very important. i was losing the battery on my miller helmet and just momentary flickering caused a huge distraction. also, the gas cups work wonders. i was able to use a little more stickout and still have great gas coverage. as greg said, a little extra stickout helps a lot.

also, not really what you are doing, but i found a back purge on my exhaust improved my welds over 30%. not sure the mechanics behind everything that was happening, but burn thrus were gone and penetration was much better with no extra heat.

Any particular Optrel? Optrel Satellite?

I have a Lincoln helmet currently. It's too dark and fogs up really easily (perhaps I'm breathing too hard?).

:cheers:

e680. It is the new Satellite replacement. The only difference is it come with a backup battery to the solar cells. I have used both Miller and Lincoln helmet in the past and while they work just fine the Optrel is just that much better. Plus if you are doing real low amp stuff you can turn it all the way down to a 5 shade. Super light weight too.

I use a gas lens too. Very helpful.

Chris

Its on the way Greg ! My tungsten is 3/32 as is my filler rod.. Changing all of it...
I have been jumping to much .. And have been staying with the thick stuff for now..
I've been playing with this and I agree a little more stick out is better...
Back purge ?

Yesterday I did improve a LITTLE bit . I figured out that I had to turn the gas down when I was doing the sheet metal. It helped..

Ok I have been thinking I could put together a small skills training class. I could get some extra talent to come in and teach some. I would have to bring in a few extra talented welders that would give up their weekend. But if you guys want to let me know who would be interested and what kind of time frame to set the class up for would be good. I was thinking Friday night to maybe Sunday at Noon. Basically a 16 hour course with enough time to get back to work on Monday. I could have some of my guys take everybody at their level. The cost might be 600 -750 bucks. We could assign 2 students to one teacher, We could make it a pretty fun weekend. If we are going to do it before summer we better get on it or do it in Sept or October. Cuz it gets real hot here in the Summer.

Just an idea. I know Greg would come just for the food.

Yep -- too much gas will do that!

Gas lens allows you to run less CFM on the gas.... I'm running maybe 12/14 cfm with a #5 cup and a 1/16th tungsten when doing sheet metal.

I don't know if that's "right" but it works for me.

I run 40 amps == but use a foot control (the new wifi version from Miller - super slick!) and am probably welding at 20 or so but I've learned to use the foot control to ramp up and slow down etc as needed. Since I'm a long time drummer -- using the "independence" of my appendages (LOL) isn't an issue for me.

RODGER ---- I'd come down for a welding class.... and some bar b q.... There's always more a guy can learn. I'm a self taught mo'roon.... and would love to get some tips and tricks!

PUT ME IN COACH!!! Sooner the better!!!!!!

Your wish is my command. May 20-22, 2011

Check the open discussion forum.

Come on Mario.....

How's that new Optrel?????

Just got it today!! Have'nt tried it yet ..... :D

Get out there man! :)