Grounding and TIG on vehicle welding

[tricky_dick]

Andy, this is great to be able to ask someone knowledgeable questions on vehicle welding. I am preparing a 1984 Jeep Cherokee for the 2005 DARPA Grand Challenge race and I recently bought a Dynasty 200 DX tig and had already own a Millermatic 251 Mig. So far, I have limited my welding to parts that are being assembled off the vehicle. Now, however, I need to do some welding on the vehicle frame and other body parts. What steps do I need to take to be absolutely sure not to screw-up the various moving parts. I have visions of accidentally welding bearings and other moving parts or worse.

[tomasharvey]

Grounding

Hey,

When your welding on things like this it is very important to have the ground as close as possible to the welding. Make sure the gound is VERY Good ie Bare metal. As you said, arcing the ring and pinion or other areas can really ruin your day.

Tom

[dyn88]

as far as arcing out your gears and bearings this is very rare to happen. you actually have to be carefull of electronics such as computers and ignition modules. If you cant disconnect these items the you shouldnt use high frequency to start your arc.

[tomasharvey]

as far as arcing out your gears and bearings this is very rare to happen. you actually have to be carefull of electronics such as computers and ignition modules. If you cant disconnect these items the you shouldnt use high frequency to start your arc.

Dyn88,

I have do work on ships and I have seen gears arced several times due to misplaced or poor grounds. I agree on the eletronic safety.

Tom
"A day with welding is like a day without sunshine"

[tricky_dick]

Thanks for the help.

[Alex]

TD,
I'm sure you know this already, but, make sure you disconnect the battery as well. If it were me, I would completely] disconnect any sort of electronics, including radio, anti-lock brakes, and anything else that could get fried, but especially the computer.

Alex

[wrench3047]

I've heard the same thing, The welder shop at work won't work on anything (vehicles) unless the disconnect everything or understand they will probly have to replace most of the electrical system after they weld if everything if left connected.

[Teeps]

I work for an ABS Manuf. and you could see we have seen a "few" ecu's destroyed this way. You have to remember every single electrical appliance on the vehicle gets a ground connection from somwhere, many from the frame on Heavy Trucks. If there is a shorter trip to a ground, thats were you'll see a problem, heh. Must have a better and closer ground to the arc point, or you will screw stuff up. Best solutions is also to disconnect the batteries, and every ecu harness you can find.

Good Luck!!!

[Andy249]

Hey guys,

I've done heaps of welding on vehicles and have killed anything electronic yet, a few times I have welded with the battery connected, bad mistake, but if you have a good work connection you can get away with it, not good practice though!!

Disconnect the battery and you shouldn't be able to do any damage to the electronics. Place your work clamp as close as you can to where you are welding, dont connect through a bearing or gear as you will most likely get tiny little arc marks on the surfaces causing premature failure.

Take your time and think it through, a few minutes thought can save many hours of anguish!!!