Welding Tricks! How to weld Steel to Cast

Here is a fun project! I show my tips and tricks when it comes to welding tabs, brackets, and most importantly , How to weld Steel plate to Cast steel.

Tools used..
Harris super Missile welding rod

Miller Multimatic 220 ac/dc multiprocess welder

Hobart Nickel99 welding rod

Barnes 4wd super duty high steer kit

keywords
fabrication
welding
tig welding
mig welding
dissimilar metals
barnes4wd
ford f250
super duty
welding tutorial
how to tig weld
dirt head shed

[josephbowers]

And with a straight face, "I made these shims from a beer can that I borrowed from a neighbor". Had me rolling.

[googleuser]

Man, it's just nice to have a channel with good tech and a likable guy. So tired of all the in-your-face douchebags with videos titled "Extreme welding tricks, you won't believe what happens! Watch to the end to see me almost die!" This channel is a gem, no clickbait, just good stuff.

[alexfrazier]

Finally something good to watch on Friday night

[jessedavis]

I was always go to 450 degrees pre welding and reheat to 450 after welding is done then peen the weld with a welding hammer while it’s hot then wrap it in a welding blanket. It’s always worked well for me. Great video Dave!

[EngiTrek]

Just a little tech behind the tig rod choice and cooling down. At the core is a difference in thermal expansion rates. Because the two different materials expand at different rates for a given temperature increase, it is in your best interest to preheat it and use a rod with a large elongation and slowly cool it. The preheating makes it so the weld does not get stretched apart as it heats up, it only gets compressed when it cools. The rod has to have enough elongation such that it can stretch enough to accommodate the two materials shrinking at different rates when it’s cooled down or else it will crack. And the slow cooling has to do with the strength of the material after it’s been heated up. The intent is to cool it slow enough that the materials can equilibrate in a uniform manner. If you cool it too fast you can get localized cooling which causes nonuniform stresses which can cause cracks. Thanks for the how to!

[ChrisZBrwn]

Felt like a Bob Ross. Awesome job Dave! The mellowness and humbleness you bring are great to watch :)

[chuckieswickedgoodfab]

Someone played a joke on me and turned down my regulator and I spent a half hour figuring out why I was welding like shit, ha ha ha, well done Dave. The beer can comment for the shims was hilarious as well.

[Brutalford]

Dammit dave you make the creative juices flow....i love your talents

[snowfarmerxx]

Back in the nineties, we used super missile stick rod… you could weld duck poop to a granite rock with that stuff… wicked expensive, though, if I recall…

[nathanhall]

70/18 or 80/18. With pre heat will weld it just fine as well and be just as strong. Done it many times

[lancehowlett]

“Beer can from a neighbor “ is why we love Dave!

[DCBuiltLLC]

I’m just glad I’m not the only one that works out of one tiny corner of a big table full of stuff! Another great video Dave! Will be doing this on my 60 soon

[bencarlson]

I'll be using that jack bolt trick in the future for sure!

[HoundofWar]

Good job.... the Bob Ross of welding! Start saying "Happy little weld."

[jeffh]

Glad I found your channel Dave. I've been watching Fred's channel for a while now. I still watch reruns of Dirt Everyday on MT. I miss your shows. You rock! 🤟

[ziptiediaries]

Good thing your neighbor had that beer can to lend ya……

[mikelee]

The shim method is definitely better than just welding as-is and allowing it to warp out of control. However, instead of using the actual hiems in place, which can result in them being heated up (melting the teflon in the joint and ruining them) or them getting covered in weld bb's, a more ideal way would be to cut some heavy-wall tube that has the same ID as the hiems, cutting that tube to be a few thousandths larger than the overall height of the hiem joint spacers. In my shop, I actually machined a few pieces of tubing to the common hiem sizes that are used in what I'm welding. Then I can use them over and over again, and they take up less space than the hiems do, allowing me get the welder in where I otherwise wouldn't be able to with the hiem in place.

[talon]

I've got some 035 flux core stainless wire I originally got for a stainless handrail job that I also used to weld mild steel to turbo, So if anyone is not set up for tig or stick they sell stainless mig wire too.

[trail-wolfx]

I'm actually just getting into welding so this is very informative. Unfortunately I only have a crappy stick welder to start but hey it's something

[Clownworldmatrixviewer]

Here’s my two cents. Push weld a root weld especially on quarter inch or thinner. Do a cover pass weld with basically 90° on the gun. You’re right about the sparks and if it is Cast steel give it some preheat.
When Cast steel is thin, like say, a pipe coupling, you can use the root weld as the
preheat.
37 years experience ⚡️🤷🏻‍♂️