Welding conduit

[bc]

Hi. I repaired a couple broken gates recently by welding on some flat bar to hold the pipe together where they break on the perpendicular joint.

Anyway, where the paint has come off, I have figured out that the gates are made out of 1" (1 5/16" OD) and 1 1/2" (1 13/16" OD) conduit that is electroplated. I have cut and welded hot dipped galvanized angle iron (in the old days) that definitely put off fumes but this conduit doesn't seem to put off any fumes.

I'm just wondering if there is any particular method for welding conduit? It is fairly thin guage and easy to burn through even with my wienie welder. I've got 1/16" and 3/32" rod in 6011, 7014, and 7018AC. If worse comes to worse, I could get out the 110v mig with .035" flux core wire which I can't get to work on mild steel although I may try some smaller wire like .030" flux core (no gas available). I haven't compared the price of conduit to the same size in mild steel but conduit may be the route to go for outdoor stuff till it gets all bent up. Thanks.

 

[thurlow]

'thout seeing it, I'm guessing that I'd oxygen/acetylene torch weld it with copper-coated rods.

 

[Anonymous-0]

I welded a lot of conduit when I was akid. It was cheap and easy to cut but if your joint has any gap to it you'll burn it up. I did it on AC at either 40 or 60 amps with 1/16" and 3/32" rod. I don't recall the rod type but it was all the supply shop had and this was back in the mid 60's. I do recall it had lots of slag though.

 

[tiresntracks]

6011 on AC works good for thicker galvanized stuff. For thin material, like conduit, I stitch weld it with a MIG. I use straight CO2 for shielding gas. A CO2/argon mix works better on thin metal, but doesn't do as well with the impurities in the coating. Your flux core machine will be more likely burn through the thin conduit, than a MIG will.

 

[Puddles]

Can't say I've ever welded a lot of conduit, but years ago I worked out of the Sheet Metal Workers union welding galvanized sheet metal. We ran a lot of Silicon Bronze, I remember we ran 98% Argon & 2% oxygen. I went on Unibraze website, they suggest 100% Helium or 100% Argon both at 40-45 cfh.
I remember this stuff being child's play to run.

 

[Dick L]

Done a bit of it. Used a Clarke 220 volt flux core .035 on 1 inch conduit. Think I will use a welding helmet the next one though. Three weeks with a sore face not much fun.
Stitch welded with eyes closed. Helmet was at the plant.
Horses got out from a broken rotten wood gate. Needed it quick.

 

[timcasbolt]

I just finished building handrails with 1" emt conduit. Used my Miller 180 autoset. Had to turn the heat way down to avoid burning it up, but eventually got the rhythm down and it came out ok. Not race car quality, but it doesn't go that fast, so it should be fine.

For stick, you'd want something that doesn't penetrate, like 6013, and a smooth hand.

 

[36 Coupe]

Time to buy a second helmet.Next use sunglasses and a news paper mask.

 

[fort67]

that"s what i weld everyday. usually .042 or.047. it takes patience and practice. Flux core is on the limit. i use mig. at the house i use .030 wire on a millermatic 185 turned down. Need to use .023.
at work we have 3 phase power units and can weld it with .035 wire and not evened turn down. 3 phase seems to have better consistent voltage.

 

[fort67]

that"s what i weld everyday. usually .042 or.047. it takes patience and practice. Flux core is on the limit. i use mig. at the house i use .030 wire on a millermatic 185 turned down. Need to use .023.
at work we have 3 phase power units and can weld it with .035 wire and not evened turn down. 3 phase seems to have better consistent voltage.

 

[JMOR]

(quoted from post at 15:55:09 07/16/11) Done a bit of it. Used a Clarke 220 volt flux core .035 on 1 inch conduit. Think I will use a welding helmet the next one though. Three weeks with a sore face not much fun.
Stitch welded with eyes closed. Helmet was at the plant.
Horses got out from a broken rotten wood gate. Needed it quick.

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