Perfect Welding Blog
From plant supports and raised beds to even an entire smoker BBQ, it’s surprising what you can create for your own home, condo, or garden armed with nothing more than a manual welding system and a little bit of patience. Our DIY expert Wolfgang Scherleitner shares his top tips for your DIY welding project.
“The key to welding is practice,” says Wolfgang Scherleitner, Head of Technical Consulting at Fronius International—and he should know. At just twelve years old, he was carrying out small welding tasks on agricultural equipment such as tractors or trailers. “I also grew up in a family of metalworkers,“ says the 47-year-old, explaining how he got into welding.
“I was fascinated by welding from an early age. Especially the idea of making something yourself by hand, joining two metals together, the heat, the arc beam, and the range of different processes and their possibilities, from oxy-acetylene welding and gas shielded arc welding to TIG welding.”
Investing in a good welding machine pays off
The master metalworker joined Fronius over 21 years ago and has worked his way up to the position of Head of Technical Competence. The welding machines would have been a familiar sight throughout his childhood on the family farm and during his metalworking apprenticeship.
“The quality of the welds and the robustness of the machines won me over,” he says, recalling the now ancient Fronius VarioStar, which he used on his first welding tasks.
And with that, Scherleitner reveals his first tip: “Invest in a good welding machine!” It doesn’t pay to scrimp on this. After all, the machine should be as durable as possible and suitable for a wide range of applications. According to our expert, an MMA welding system, such as the Fronius Ignis 150, is a good way to get started.
Beginner-friendly welding processes
There’s no complicated technique, gas feed, or filler metal when welding with stick electrodes, making it perfect for beginners. The slag that arises when the electrode melts also protects the weld from contamination, making it more forgiving of mistakes.
What’s more, MMA welding is an exceptionally mobile process—wind and rain are not a problem. In theory, you could even use it to weld underwater.
Gas shielded arc welding for quick, clean welds
Our pro recommends the Fronius TransSteel 2200 as a real all-rounder for gas shielded arc welding. Thanks to the automatic wire feeding and continuous deposition rate, you can create precise, visually clean welds.
“The welding torch included in the set sits real well in your hand. This makes it so much easier to guide the torch, especially for beginners,” explains Scherleitner. With the MIG/MAG process, you can also avoid time-consuming rework (such as knocking off the slag), which makes it a whole lot quicker.
However, MIG/MAG only works when the air is still, as otherwise the protective gas shield cannot be formed. For more details, see here: TIG, MIG/MAG, or electrode welding.
You can also find out how to set up a welding machine correctly on our blog under welder settings.
Before you start: The necessary safety precautions
Once you’ve chosen a welding machine, you can just get started, right? “Wrong! You also need to have the right protective equipment,” warns our expert.
Scherleitner stresses the importance of always wearing a welding helmet, gloves, and a good jacket when welding: “You can give yourself arc eye if you’re not careful,” he says, referring to a well-known occupational illness.
The UV radiation from the arc damages the retina, which in turn triggers an inflammatory reaction. Typical symptoms are itchy, watery eyes and feeling as if there’s sand in them. “This happens quicker than you’d think, so never, ever weld without your visor down!”
If you’re on the hunt for suitable protective equipment, have a look at the Fronius online shop.
Find the right DIY welding project
If you’re ready to have a go at welding, take a look at this list of welding projects we have put together with varying degrees of difficulty—from a simple wind chime to your very own smoker BBQ.
1. DIY welding projects for beginners
Wind chimes are ideal for practicing small welding spots. They don’t require any complicated or long seams, so they offer the perfect opportunity to get a grip on the arc and new welding machine in your own time. You don’t need much either; a few pieces of old metal will do. You can weld these together creatively and then hang the wind chime up with some wire later.
Shelves can be made in a similar way and are ideal for storage in your workshop. Straight cuts, easy joints—they are also perfect for beginners and at the end you’ve made a highly practical everyday item.
A trellis for climbing plants can also be welded just as quickly: arrange the metal struts as desired, tack them, weld with a steady hand, and you’ll have made a unique and stable climbing support in no time at all.
Tip: Bronze or copper-colored material develops a natural patina when exposed to water and air, which gives a charming, vintage look.
Your hand-made fire bowl is sure to impress at your next garden party. A round or square design made of thick sheet metal gives the necessary stability and can be a real eye-catcher. It’s also an opportunity to give gas shielded arc welding a go.
2. DIY welding projects for experienced hands
Once you have a bit of practice under your belt, you can also try your hand at something a bit more challenging, such as a raised bed. Weather-proof and stable, metal is best for your garden or balcony, instead of wood. It’s important to draw a sketch as you’ll need exact dimensions and strong welds if it’s to hold tight.
Upgrade your entrance area with your own modern, industrial-style coat rack. Cut metal pipes to the desired length and thoroughly clean the contact points. Tack the individual parts together to create a frame and then weld it with uniform seams.
You can then hang your unique piece from the ceiling or, alternatively, you can attach cross struts and use it upright with coat hooks. If you’re in need of some inspiration, look no further than artist Andrea Stahl, who specializes in welding furniture!
3. DIY welding projects for advanced welders
Scherleitner recently made a smoker BBQ. “That was a pretty big project,” he admits. But with a bit of practice, it’s no problem: make a sketch in advance, determine the dimensions, and procure the material, such as a 16-inch thick-walled pipe which holds the heat well.
Next you need to cut all the parts to size and make cut-outs for the chambers. Then tack, sandblast, and fit the covers, handles, flue pipe, frame, and BBQ components.
A self-welded garden fence or garden gate also requires a certain amount of skill, as it involves multi-part structures with movable elements.
Tip: Make sure you align and fix everything in place before welding with screw clamps or welding positioners, so that the fence turns out straight and the gates close properly.
Another similar project for advanced welders is a pavilion. In principle, you need to pay attention to the same things as for the garden fence. But watch out—the pavilion must be structurally secured to prevent any accidents.
Without precise planning, exact angles, and stable joints, it can be dangerous. Make sure you practice until you are completely confident in your welding ability.
Show us your welding talent!
We wish you every success with your DIY welding projects and would love to see your photos. Feel free to tag us on Instagram or Facebook (@froniuswelding) when sharing your masterpieces on social media!
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