Weld a handle to a Drip Torch tank using filler rod in 3 minutes or less.
Wear appropriate safety equipment throughout welding.
- Welding Helmet
- Long-Sleeve Shirt and/or Welding Sleeves
- Welding Gloves
1. Sharpen Tungsten
Sharpen 1/8" 2% lanthinated tungsten.
- Place tungsten in cordless hand drill chuck.
- Clean 6" bench grinder wheel using grinder stone dresser to remove any contaminants from the wheel, if necessary.
- Stabilize the drill on your hip and rest the tungsten on the tool rest to get an even angle while sharpening.
- Sharpen to approximately 60-20 degrees. Ensure that your grind is concentric to the axis of the tungsten.
SAFETY WARNING: Use safety glasses and dust mask while grinding to prevent inhalation of tungsten particles. Ensure proper ventilation or turn on a fan pointing away from you. Tungsten particles are hazardous heavy metals.
DANGER: Do not grind 2% thoriated tungsten tungsten as it is radiated.
2. Welding Set-Up
Set up the welding machine and turntable with appropriate settings.
Miller Syncrowave 250
- Amperage Adjustment: 130 (1)
- AC Balance: 10 (2)
- Crater Time Switch: Off (3)
CobraTurn Digital Turntable
- Turn dial to 10 RPM
Use a #5 gas lens cup, a standard gas lens collet body, and sharpened tungsten.
Remove hand rest from welding table and place handle fixture onto the turntable.
3. Tank Set-Up
Place drip torch tank onto the handle fixture with the drilled hole in the Tank Top oriented up.
Center a handle evenly along the top of the tank. If one leg of the handle is shorter, place it nearest you.
4. Tack Handle
Tack the handle leg nearest you to the tank and ensure even placement of handle.
Rotate the fixture 90 degrees clockwise and tack the back leg in place.
5. Weld Handle
Begin welding the back leg of the handle, starting at the tack and moving around the base of the leg, using a 1/8" 4043 aluminum filler rod in a clockwise direction. End the weld by overlapping the start and end point with large tack.
Rotate the fixture 180 degrees on the turntable and repeat the weld on the front leg of the handle.
6. Inspect Weld
Inspect the full range of the weld to ensure complete fusion. Re-weld segments needing additional coverage.
Inspect the inside of the tank to ensure there is no burn-through. If there is, have the tank undergo leakproofness testing to detect any leaks. If leaks are detected, have a welder experience with patching fix the affected area(s).