- Joined
- Oct 17, 2010
- Messages
- 2,424
Man, I just want the handle to stay stuck!!!!!![]()
I can tell you how to make this pretty foolproof, but, it's not going to happen with a 110V mig or a buzzbox.
I've always hated handles falling off, and once I started having to weld a large "nub" on the end for rolling mill work, it became more dangerous when it happens.
If you're using solid bar for a handle, you need to chamfer the end heavily before you weld, I recommend 5/8-3/4" bar personally. I use 2" long pieces of this for holding with round tongs for rolling mill. Your tack welds you run reasonably low power and penetration so they're not too deep on the billet, but for the handle, you want to be running pretty high. A small 220 welder, I'd be running at least for the 1/4" plate single pass setting, or higher, with lots of wire.
Chamfer the piece enough that your first pass of heavy weld replaces basically the chamfer material, but doesn't add much circumference to the handle bar, then do another full pass, moving the pool up and down between the handle above the first weld, and the billet past the first weld. The handle wont fall off at this point, even when you roll or forge it flat.
If you're using tubing for the handle, get thicker wall tubing, and do the same just don't chamfer as heavy, and run the second bead heavier (you need it thick enough that you can run a heavy bead without burning through the tubing wall, because that's where it usually falls apart), or use a piece of square bar, the same size as the tubing, for the first 4-6", welded to the billet as above, then weld the tubing to it. This is the best option if you like to have vent holes in the tubing.
Personally, I've just come to prefer using the nubs, with large round bit tongs. You can keep the tongs out of the fire and quench between heats. Once you get used to it, it's not any more cumbersome than the handle, but gives you more flexibility, plus, one bar of 3/4" round will last you a very long time.
To be clear, this is using a 220V welder with shielding gas. Flux core is convenient for outside work, but is far inferior for this kind of stuff.