10:06 PM
@IanC - How are you doing your butt welds? When welding sheet metal, you have to just put a huge amount of tacks all along the butt joint, spacing them out as you place them. You CANNOT do a continuous bead on sheet metal as it will just continually burn through. It will also put a lot of heat into it which can warp it.
You want to put a tack in one spot, then move up about 3 to 4 inches and put another tack. Continue doing this for the length of the weld space, then go back to the beginning. Place your next spot weld at this point 1/2 way between the first two, then on down the line like that. On the next pass through, you only want to go 1/2 way through between the welds like you were doing, but then only do it to every other space. The ENTIRE idea is to fill it up with tack welds.
Once all the area is tack welded and it's a solid weld, you take a grinder (flap disk works the best) and carefully clean up the area making the welded area flush with the sheet metal. If you find any small holes left, hit those areas with tack welds to fill them in. Then knock it down again to level it out.
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