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Old 10-17-2014, 04:10 PM   #11
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Re: Welding?

I have a Lincoln Weld-Pack, flux core. I think it was almost $300, great little welder.
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Old 10-26-2014, 04:19 PM   #12
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Re: Welding?

I started out stick welding in junior high so thats all I knew for many years. Fast fwd to age 40 or so I bought my first used mig welder and have built a crap load of items. Needed one bigger so I bought a 250x miller for really big metal…. for such things as BBQ trailer smokers etc.

If you plan on doing a lot of sheet metal welding I would get in to a smaller one like a 185 or something along those lines. My 175 is an older model but I have build almost everything you can think of. I just needed something with a bigger duty cycle
Here is my school bus conversion thread

Pics of my conversion @ photobucket
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Old 01-31-2015, 10:49 PM   #13
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A couple thoughts about welding, first make sure the metal your welding to isn't galvanized as that produces pretty toxic fumes when welded. Also, I don't know what your work area is set up like but most welders run on 220v & don't have very long cords. This may or may not be an issue. Considering your lack of welding experience I would go with rivets. But I can't even begin to tell you how fun welding is. If you have a technical school that has welding courses & it interests you, then take a class or two. I've only been welding for about 5 years & have scored some great deals on eBay. Now I look for any excuse to cut & melt steel
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Old 02-01-2015, 12:36 AM   #14
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I've welded galvanized metals. Ventilation and breathing protection are a good idea. But it can be done. My bus has some factory welds on galvanized areas.
Grinding, cutting, or welding that stuff is nasty and I do hate it. I used to plasma cut huge sheets of galv-anneal. I would wear a respirator. The "old timers" laughed and jeered. But now one has cancer.
Always weld safely!
I'm really not a great welder. Good enough but I always tried to find a machine to run. Like that plasma table or the brake.
I think rivets are definitely the way to go for this job the op is doing. I'm riveting mine the same way.
Try the $70 harbor freight riveting tool. I bought one. Still have to try it out.
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Old 02-01-2015, 07:12 AM   #15
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Have you considered taking out the window and replacing it with a pre made panel? That would, I think be faster and easier. A number of ways come to mind on how to fabricate the panels. I think Lorna did that?
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Old 02-01-2015, 09:39 AM   #16
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I replaced two windows with panels. I just cut 1/4 inch thick aluminum to 25.5 inches by 25.5 and glued it in place with silicone caulk then put brackets to hold it in place using self drilling screws.
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