The photo shows the first weld I did with my new guide. It is the straightest bead I have ever made with my wire feed welder, and it was very easy. This weld bead is about three inches long.
UPDATE: My 2004 Lincoln auto-darkening helmet uses 2 AAA batteries. Because the helmet always darkened as it should, I had not replaced them. I did replace them recently, even though they were far from "dead" and now the lens in my helmet darkens, but not as much as it has until now. I can now see the weld area much better. Many helmets use solar cells and lithium-ion batteries. Check your manual and see if it is possible to replace the batteries in your helmet. That and replacing stained and pitted plastic lenses my make it much easier to see what you are welding. Protective clear lenses that are not stained or pitted can be dirty. A good dust removal can help, too.
Step 1: Tools and materials
- Concrete floor
- Round rod about 3/8 inch in diameter
- An old automobile license plate made of aluminum
I am using aluminum for this welding guide because weld spatter will not stick to it.
Step 2: Bend and roll
Step 3: Cut the license plate and add a crease
Step 4: How to use this guide
If the roll on the license plate does not ride against a good place on the nozzle, making the bend in the license more oblique rather than a right angle will lower the roll so it is closer to the joint surface. Or, you could also straighten the license plate and bend again.