Chromoly roll cage - Welding Tips and Tricks

Louie wrote: Some may disagree? I guess Jody disagrees with you too. He has at least a half dozen videos on welding chrome moly tubing and in every one he is using 0.045 wire or 1/16th wire. He even has published advice on how to select filler wire. Your advice is completely opposite of his. No offense, but I am taking his advice over yours every time.

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Well, to quote Jody in that video within the first 20", "There is NO definitive answer on what size wire as it all depends upon the application.". Guess you missed that part.

"Rule of thumb" is just that, a general guide. It does Not dictate what you must, or should not do. It is a basis for making a decision. If you read carefully exactly what I wrote, you might understand the specific conditions for which I would choose a single pass with a 3/32 wire. I have never said 2 passes would not be a good choice too. I only said, "full penetration, single pass, up the amps".

The very real case for undercut with smaller wire outweighs the risk of using a larger wire at higher amps in many people's book. And to be honest, 0.083 wall tubing isn't really "roll cage material" in any sanctioned sport. Minimum that I have ever seen is 0.120. I have much respect for Jody and his vast experience, but I am fairly certain in nearly EVERY video he will openly admit he is NOT the end-all, be-all on welding. There are numerous folks who do this for a living, and some of these good people I know and base my recommendation on their counsel. Because their frames pass RACE SPEC every time.

I suspect that if the OP welded up 4-6 sample pieces, cut and etch them fully, he would find numerous points of lack of fusion/penetration because he was trying to control the heat (using lower amps based upon wire diameter) and even a cover pass would not provide the strength necessary for a roll cage to survive a catastrophic crash. And if he did get full penetration with 0.045 or 0.063 on 0.083, dollar to a donut he has undercut all along that weld. Do you know anyone who would feel that is okay? Bet "Jody" would discard that tube in 1 second flat.

So Louie, you are free to choose for you. I am merely offering the OP another option to consider.

Well, to quote Jody in that video within the first 20", "There is NO definitive answer on what size wire as it all depends upon the application.". Guess you missed that part."Rule of thumb" is just that, a general guide. It does Not dictate what you must, or should not do. It is a basis for making a decision. If you read carefully exactly what I wrote, you might understand the specific conditions for which I would choose a single pass with a 3/32 wire. I have never said 2 passes would not be a good choice too. I only said, "full penetration, single pass, up the amps".The very real case for undercut with smaller wire outweighs the risk of using a larger wire at higher amps in many people's book. And to be honest, 0.083 wall tubing isn't really "roll cage material" in any sanctioned sport. Minimum that I have ever seen is 0.120. I have much respect for Jody and his vast experience, but I am fairly certain in nearly EVERY video he will openly admit he is NOT the end-all, be-all on welding. There are numerous folks who do this for a living, and some of these good people I know and base my recommendation on their counsel. Because their frames pass RACE SPEC every time.I suspect that if the OP welded up 4-6 sample pieces, cut and etch them fully, he would find numerous points of lack of fusion/penetration because he was trying to control the heat (using lower amps based upon wire diameter) and even a cover pass would not provide the strength necessary for a roll cage to survive a catastrophic crash. And if he did get full penetration with 0.045 or 0.063 on 0.083, dollar to a donut he has undercut all along that weld. Do you know anyone who would feel that is okay? Bet "Jody" would discard that tube in 1 second flat.So Louie, you are free to choose for you. I am merely offering the OP another option to consider.

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