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For Welding auto body panel with flux core, beginners find it overwhelming and a bit challenging due to the less authentic online information.

So, I researched hours to find the most effective steps to weld auto body panel using flux core. This is what this guide is all about.

Are you ready to dive in? Lets go

flux core welding auto body panel
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Can You Weld body panels with Flux Core Welder?

Luckily, using flux core welding to weld auto body panels is a good idea, especially if speed is your primary concern.

Although tig welding serves excellent results in welding thick sheet metals, you can still get the most out of your welding through flux core by applying the correct welding wires and following the right directions.

How to Weld body panel with Flux Core (Steps)

Flux core tends to be a popular choice for welding thicker metals. You can go through a body panels following the proper steps.

So let me show you the way to do that:

  • Step-1: Get Your Hands on Safety Gear

No matter what, you must collect all the necessary safety dresses needed before you start welding the body panels. Chances are the flux core may produce too many fumes during a weld. So don’t forget to cover up yourself by wearing safety gear.

In this case, you’ll require a particular welding helmet, a pair of gloves, a single face mask, and a pair of safety boots. Having a welding jacket is optional. 

  • Step 2: Get the body panel surface Clean

Although the flux core welding process can smoothly deal with dirty metals, I suggest cleaning up the body panels surface before you begin welding. In this way, you’ll find it way more accessible and less time-consuming to weld, trust me.

So, as for cleaning the surface, get your hands on a piece of the brush to wipe away the existing dust. In case you notice anything like oil, grease, or such things, use a piece of rag to get it spick-and-span.

  • Step-3: Plug in the Welder

Before you plug your tool into its desired location, load the handpicked wire into your welding machine. If you’re new and don’t know how to do that, rely on the user manual to get the necessary details regarding wire-load.

  • Step-4: Turn the Current Strength medium

Selecting the ideal current strength depends on the type and thickness of the metal. As body panels tend to be much thicker, turning the current strength medium is a wise idea to get the best outcomes.

After welding a bit with medium strength current, you may increase the current flow for better weld. The heat of your welder should be mediocre in range.

  • Step-5: Begin Flux Core Welding

Have you adjusted everything correctly? If so, then start welding by correctly placing the body panels. Once you set it up, start the welder without any rush. Go on welding without any movements, as it may eventually end up with inappropriate welding.

  • Step-6: Shut Down the Welder

After a successful body panels welding, turn off the welder straight away. Please don’t make the mistake of touching the metal immediately, as you may find it hotter.

Let it get completely cool by waiting for a while or so.

What Wire to Use for Flux Core Welding body panels?

These days, numerous types of flux-cored self-shielding wires are available to use for welding body panels. But according to my observation, AWS E71T-11 and E71T-GS stand out for meeting the AWS (American Welding Society) classifications.

Talking about the diameter, you better choose a wire one that is around .030” to .035″ for most of body panels. They will perfectly suit thicker sheet metals.

What Flux Welder Settings to Use to Weld Body Panel?

Let’s take a look at the following range of settings you should use to weld body panels

1. Voltage:

Most flux core welding requires an input power of 230 or 460V to get the work done, especially while welding stainless steel and sheet metals. You may use that voltage for welding body panels. You should play around a little bit with power and voltage to find your best spot.

2. Wire Size:

Several types and sizes are available for welding body panels. Among them, you better stick to .030” to . 035” to get the best results.

3. Frequency Level:

Around 60 Hertz is the ideal frequency level.

4. Current Strength:

Turn the current strength level as possible as sheet metals appear thinner and prone to get damaged by higher heat.

Last Words

Body panels welding with flux core have become a snap today. Here, I’ve shared the most basic way to get it done.

Follow the steps correctly, and don’t forget to get the right wire for flux core welding body panels. If not, then the task won’t be successfully accomplished!

Maidul Islam

Maidul Shakil has an extreme love for welding. Welding metals and joining them is his hobby and he has also got a vocational training on welding. He strives to learn and teach welding processes and different gears to beginners and newbies. Cutting metal, fusing them and polishing to a shiny surface seems interesting.