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manual abstract
Contaminants will interfere with the welding process, and may cause noxious gasses to be produced as they are heated during the welding operation. 2. Always connect the Ground Clamp to another cleaned location as close as possible to the work area (no more than 12” away). NOTE: Always wear and use ANSI-approved personal safety clothing and safety devices to reduce the risk for injury. Spot Welding Washers using the Magnetic Washer Tip 1. Thoroughly clean the area to be worked on using an angle grinder, powered wire brush or similar tool. 2. Attach the Ground Clamp near the area to be repaired. 3. Turn the Function Selector to the TIMED setting. Set the Timer Control to between 0.1 and 1.2 seconds. NOTE: The time must be adjusted for the thickness and relative density of the work material. In general, larger thicker washers will require longer welding time. 4. Insert a flat washer into the Magnetic Washer Tip. 5. Using the gun, press the washer against the dented area. Squeeze the trigger. The washer will be welded to the work material. Release the Trigger. 6. You may use washers of different sizes and thicknesses for different dents. Larger washers will have more pulling power. Be sure to use washers that are NOT galvanized or electroplated, and are free of rust, grease, dirt or other contaminants. 7. If necessary, you can spot weld the washer, then heat the surrounding area before pulling the washer. Heating the surrounding area will anneal, soften the metal making dent removal easier. WARNING: Galvanized and electroplated metals generally have a zinc based plating to resist rust. When heated, zinc gives off a harmful, potentially poisonous gas. Do not weld with electroplated or galvanized materials. NOTE: Welding is a complex operation requiring training, skill and practice. We strongly recommend professional training before attempting any welding operation. This manual is intended only as basic information and cannot cover all aspects of the welding process. Schematic of Washer Welding REV 08b Using the Extractor Hook 1. Thread the Extractor Hook (Pot Hook) onto the slide puller assembly. Fit the extractor hook onto the washer. 2. Hold the Hand grip with one hand, and pull the Striker back sharply against the handle. This action will pull out the dent. Repeat as necessary. You may need to weld on additional washers at various spots to pull out the dent completely. 3. To remove the washers, grip the washer with a pliers (not included), and bend back and forth until the washer breaks off. 4. Using a grinder (not included), remove the weld spot from each repair location before finishing the dent repair. About Spot Welding Spot welding is used to join two items of metal together. A high energy electrical force is applied at a small location for a short time. This electrical force causes the two items of metal to melt and fuse together at that spot. If the electrical force is not large enough, if the duration is too short, or the metal is too thick or is dirty, the weld may not properly fuse. If the electrical force is too high, if the duration is too long, or the metal is too thin, the metal may burn through; “blowing out” and causing a hole in the work material. In auto body repair work, washers or pins may be welded to a spot on the vehicle body to allow a dent to be pulled out. The washer or pin is then removed, and the spot ground smooth for finishing. In cases where there is a hole or severely damaged body panel, a new sheet may be spot welded over the damaged area to provide a new surface for finishing. Proper welding is a skill that takes some time and practice to acquire. Experienced welders will usually make one or more practice welds on scrap material, to adjust these variables, before making welds on the work material. Using the Shrinking Electrode 1. Insert the Magnetic / Shrinking Electrode in the Gun with the rounded Shrinking end protruding. 2. Set the Ground Clamp as close as possible to the damaged area. 3. Set the Function Selector to CONTINUOUS. 4. Place the Electrode on the damaged area and squeeze the trigger. The electrode will heat up, as will the work material. Use the electrode to press the heated material down into shape, reducing or “shrinking” convex dents. CAUTION: Be aware of your working time and do not exceed the welder’s Duty Cycle. Using the Carbon Electrodes The Carbon Electrodes can be used for warming or tempering, spot welding sheets together, crack filling or cutting sheet metal. CAUTION: Be aware of your working time and do not exceed the welder’s Duty Cycle. For Warming: 1. Insert the carbon electrode into the gun and tighten into place. 2. Connect the Ground near the work area. 3. Set the Function Selector to the “CONTINUOUS” setting. 4. Contact the metal with the electrode, holding the trigger down, and moving the electrode continuously over the surface. 5. When the surface has been heated, release the trigger and remove the electrode from the metal. 6. Warming the ...