How to Weld Galvanized Steel Sheets Together

What You'll Need
Wire welding brush
120 and 60 grit sandpaper
Vice grips
Welding gloves
Body metal hammers
Liquid metal filler
Welding face mask
Long sleeve shirt

In order to properly weld galvanized steel sheets together you will need to be experienced in welding. If you are not, then you need to find a person that is. There are a few things that you need to make sure that you are aware of. You also need to have the right tools so that you can get this job done fast and effectively. Remember, galvanizing steel sheets is not a type of a job that you should be taking lightly, make sure that you are aware of the task at hand so that you are fully prepared for what is expected of you.

Step 1 – Set Up

The first thing that you are going to have to do is get the lighting set up for the area that you are going to be working in. The light needs to be direct and bright. You will also need to take the time to make sure that there are no rags that are flammable and that the area is clear of all clutter and debris. Take the time to tell others that they should not be in this area while you are welding unless they have the proper eye protection.

Step 2 – Clap

Once the area has been set up you are ready to get the 2 pieces of sheet metal that you are welding clamped together. Make sure that they are fitted together tightly and have a flush seam. Decide if you want the metal to overlap or if you want it to line up perfectly against each other. If you want to line them up against each other, then you should have a piece of wood laid underneath the seam where you will be welding. The edges that are metal need to be level. Ensure this with your hammer so that you can do away with any of the rough edges.

Step 3 – Clean

You are going to need to make sure that the sheet metal is going to be as clean as possible. If it is not, then the weld is not going to be able to stick very well if at all. Use your wire brush and sandpaper to clean the entire area. If you have any stubborn spots, then get out your grinder and finish them up. Make sure that the sheets are completely clear and free of debris before you begin to weld.

Step 4 – Setting Up the Welder

You are now ready to begin to set up your welder. Make sure that the power is turned off while you are doing this. Start off at a minimum power with a 22 gauge. The low heat setting will need the wire feeder speed to be set low, right around 3 is where you will need it. Your grounding clamp will need to be attached onto your metal, make sure that it is out of the way of where you will be welding.