Welding Wire Size
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Joined: Feb 2013
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From: British Columbia
Welding Wire Size
I'm new at welding the last few years. I use .035 wire which I think is pretty common. It's brutal on sheet metal for burn thru even turning things down, for me anyways lol. There is a smaller wire available. I think it's the .024 size? Anyone have any feedback on this? Does it change much or easier on burn thru? Thanks guys.
Cross-Country
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I have done a fair amount of welding before I retired as tool and die maker but it was mostly tool steel and TIG. Just bought a "flux core wire" welder, similar to a mig except it uses flux core wire instead of gas shielding. It uses .030 wire or the .024, I am using the .030 and it takes some practice to control burn through. The trick is to not run a bead but short tack welds spaced apart then come back and add more short tack welds until you have filled in the area you are welding. This helps prevent burn through and keeps from putting too much heat in one area and causing the sheet metal to warp.
I have not looked at a "welding supply" store, been getting my supplies at TSC and Menards and have not seen any .024 wire. I also hear it is more expensive and harder to find than the .030 wire. I am not a professional welder either but did a fair amount of TIG welding up tool steel at my job before I retired. Jim.
I have not looked at a "welding supply" store, been getting my supplies at TSC and Menards and have not seen any .024 wire. I also hear it is more expensive and harder to find than the .030 wire. I am not a professional welder either but did a fair amount of TIG welding up tool steel at my job before I retired. Jim.
Cross-Country
Joined: Jul 2021
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I agree. The problems are I haven't found anything smaller than .030 locally and I do not have room for adding tanks for gas. I am also doing the bulk of the welding outside where a small breese can blow away your gas. Jim.
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From: Angier, NC
I don't even know if they make flux core smaller than that?
Dave ----
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Joined: Dec 2020
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From: Stow, MA
The smaller wire does make a significant difference when welding thinner material like autobodies. Along with the thinner wire, you will also need the matching wire feeder rollers for the smaller wire.
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From: British Columbia
Just to update, I am using .023 wire and it seems easier to lay down spot welds, for me anyways!
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That's the way to go --- I use ESAB .023 on most sheet metal body panels (25/75 on the gases) during fabrication / restoration, then use Silicon Bronze (pure Argon gas), a "brazing" technique on the MIG machines, as a filler to limit the amount of "bondo" -- the latter is very easy on thin body panels, uses low heat and prevents warpage.
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