How To Make a Perfect Weld || LIFE HACK

**Andrii Pysarenko** · Aug 15, 2021, 12:22 PM

**BuffaloJohn** · Aug 16, 2021, 05:25 PM

I'm a self taught welder - started out on stick in 1976 and learned MIG in the mid 90's and AL MIG about 20 years ago. I've read a bunch so I could learn and I have questions...

Why are you doing a butt joint and then grinding off the weld? You didn't get penetration enough to grind off most of the weld.

And if you do a butt joint, why aren't you making room for weld? The strength of the weld comes from having the original and weld having sufficient material with good contact. You should have cut back the edge on all sides of both pieces and then filled that space with weld. Doing it on the surface and then grinding it away substantially reduces the strength of the weld.

And when you ground off the outer edge of the corner, it sure looked like you ground off all of the weld. Did you see that? That joint is just metal butted together.

If you do a search for Weld Joints and look at the images you will see how it is supposed to be done.

**NortonDommi** · Aug 16, 2021, 08:19 PM

I agree that the strength is in the weld but sometimes for decorative reasons welds need to be ground. Handrails in architecture, marine work etc. are just two examples. Sometimes in a fabricated part welds need to be ground for fitment. I need to grind welds often for a variety of reasons but hopefully I have full penetration,(I do check with inspection mirrors, light and sometimes test pieces to make sure I have my settings correct). Brazing or Bronze welding is sometimes better as it can give very smooth fillets and is extremely strong in a well prepared and made joint. Reynolds Tubing recommends Brazing and Bronze welding as the preferred methods for their high strength tubing.
'Blending' with epoxy in corners and around tube joints was used when making 'Choppers' some years ago,(Crikey was that last century?),and is great if painting.