mig vs tig vs stick vs flux body panel replacement

[davidomilligan]

Too many welder choices and many people saying different things. I've ruled out flux and stick for automotive panels. I can't figure out whether to go mig or tig. Yes I realize tig takes more precision. Detroit speed seems to like tig welding ....overhaulin seems like mig fans. What do and have you guys used for replacing body panels what are pros and cons of each

[jlcustomz]

I have both, a mig at home & mig & tig at work. If you could only choose 1 for automotive steel use at home, you're best to start with a mig. Mig is easiest to do something with , but hard to not be messy with, particularly on the thinner stuff that can't be run hot & continuous. Auto sheet metal requires lots of small tacks spaced apart with ample cooling time to not warp. On the upside, you can do the tacks much quicker with a mig & it's hand control & auto feeding wire (and auto darkening helmet), But the time you save is mostly spent back in grinding time, again going slow & jumping around to avoid warping. Mig is more forgiving of less than perfectly clean metal, such as some with not all of the galvanized coating removed. I do not ever care to try mig again for aluminum or stainless.

Tig will give you a much more precise flatter weld with more controlled penetration that takes less grinding. Tig is also king for a weld that you want exposed for all to see & nearly mandatory for items you want to hold fluid & pressure. The foot control of a tig is awesome when you're in a sitting comfortable position, not so when you're not, though there are optional hand controls. No spatter either , unless you got some crappy metal.

Lots of different opinions here, but if you're not an experienced welder with both types, get a mig now & consider a tig later. Get a decent one with 75/25 mix gas.

[jazz]

What he said!!

[raustinss]

X2....way too easy to put too much heat into a panel of your a novice at TIG....and unless you're a expert metal worker the panel can quickly become garbage

[Auto Rod Technologies]

VERY good explanation. and I agree 100%.

However I would like to add that now that I have gained some experience with a Tig welder I find that I spend much more time with a Tig welder now than I do with a Mig welder. But I also do more fabrication now than I have in the past.

If you are doing general panel replacement or welding I would go with a Mig welder. I tend to use mine only for spot welds anymore, I tend to use the Tig for just about anything else. Weld seams are much nicer with Tig, along with pipe welding or sectioning. Tig also takes a lot longer to learn and isn't as convenient unless all of your welding is on a bench.

[Auto Rod Technologies]

I might add that you can buy a decent 110V mig welder that will do a good job for under 1k.. I spent $700 on mine and it does a great job.
You may be best to get something like that and save up more money and get yourself a nice Tig machine later.

[MonzaRacer]

Other thing is proper gaps use thinner wire so you can keep amps down. Another thing is f you figure it right the tacks welding the metal together contract as they cool and pull up he panel straighter. Most people try to tighten up the gaps, then add to much heat, then everything gets stressed and warps.
I like 0.023" and co2/argon mix. Keep the gaps in 0.040" range and work in steps too keep it from building too much heat in any one place too prevent warping.

[davidomilligan]

Good stuff guys thanks very useful

[jlcustomz]

Forgot to mention the .023 wire for thin sheet metal. Another downside of mig welds is they start cold , & you'll be making a lot of starts. The smaller wire will get hot faster & be a little more precise for you. Some guys even go to the extreme of cutting off the ball at the end of the wire before each tack, but I'd rather swap to the tig than do all that each spot weld.

As far as brands , get something decent. Miller is one of the best, Hobart ( owned by miller) is slightly cheaper, but so are their controls. Lincoln & other 130 to 145 models can also be sufficient for sheet metal. Have a miller 210 at work, it's nice, but as said, don't spend the money on a bigger one than you need, save it for a tig. I agree 100%, that in a shop situation with practice, you aint gonna want to use the mig for more than tack welds & messier projects. A tig can even smooth out some messy looking mig welds, making you not like the mig so much. Having a tig in the future is a worthy goal. An upside to getting a tig these days I didn't have a choice on is the new iinvertor models use less power & are smaller & MUCH lighter. Thats why my Miller synco 200 is still at my work & not at home. I unloaded it with a forklift.

Baby steps though....

[minendrews68]

To me the Tig is a little more learning curve than the Mig. I've done both and like both. I'm just better at the Tig welding because I've used it more. I am not a welder as a profession. But have done a little in the past. Good write up too.

[davidomilligan]

Other thing is proper gaps use thinner wire so you can keep amps down. Another thing is f you figure it right the tacks welding the metal together contract as they cool and pull up he panel straighter. Most people try to tighten up the gaps, then add to much heat, then everything gets stressed and warps.
I like 0.023" and co2/argon mix. Keep the gaps in 0.040" range and work in steps too keep it from building too much heat in any one place too prevent warping.

I have seen special clamps on ebay that look like they hold the perfect gap for welding panels anyone used them ?

[Nothingface5384]

Ive tried to fluxcore body panels...too hot
added the argon to mig and good to go
stick is easy to learn, just need ti get your work angle down and speed so everything looks all purdy lol
ive used oxy and apparenty Tig is same technique as(drae cresent moons) oxy but with a voltage pedal?

[daredvl22]

Agree with what everyone above has said. I started with MIG, then purchases a spot welder (panel replacement for factory appearance) then purchased a TIG. I've go the MIG and Spot welder down. TIG welding is a whole other animal. It takes practice and patience. I recommend all three types, if you're able to invest that kind of $.

[dhutton]

"I have seen special clamps on ebay that look like they hold the perfect gap for welding panels anyone used them ? "

I have some but I find them to be a PITA to use. Too much work for too little return in my opinion.

Don

[minendrews68]

In my opinion, just stay away from the flux core wire. Just doesn't work nearly as good as the gas shielded welders.

[jlcustomz]

My first welding experience was the old oxy/ac torch & have one of the henrob cobra torches. Great on smaller sized sheet aluminum & 18 gauge or thicker sheetmetal, like your MUCH older cars. Didn't bother mentioning , because it's not so great for thinner sheetmetal like 20 to 22 gauge.

Learning first on a torch does make a tig seem not as hard as some say to learn though, same basics.