Gas Free Mig Welder Conversion - Gas-Free MIG Welding

We used a Miller 375 Extreme plasma cutter to produce surgical-quality cuts on the 3/8-inch steel plate, and then used a die grinder to do the final sizing.

Look to the bottom left of the steel patch and you will see one little tack weld. Steve made this one tack weld and then checked to ensure the patch was perfectly aligned.

Once Steve was sure it was a good fit, it was time to add some more tack welds. Notice the gnarly, smoky white traces around the tack welds; this is from the flux-core in the MIG wire.

With the patch solidly tacked-in Steve moved on to welding the top and bottom. Notice the top weld is cleaned off thanks to using a wire brush.

To demonstrate for readers two different methods of filling a gap Steve left an overhang of steel that he cut flush with a die grinder to be used as filler in the gap.

Notice how nice the welds look, and all of this was done outdoors while the Santa Ana winds were blowing like crazy. The next step is to finish the welds off with a body grinder and then the repaired area will look as good as new.