Mig Welding

[ChallengerHK]

I have a lot of questions about this, but I need to explain what I'm up to first. I'm working on a large art project that I'm trying to get into a gallery. For part of the project, which will really hold the rest together, I need to have some 1/2 inch square steel rod welded together, essentially two frames, s smaller one inside a larger one. There will be other small pieces that I need to create, and a stand about 4 feet tall for the whole thing. Local metal fab shops want about $500 to do this, whic I think is outrageous, but maybe I'm being unrealistic.

Anyway, my thought it to get a cheap mig welder from Harbor Freight, steel rod from Home Depot and do it myself. I've welded with gas but never with a mig rig, and I was never that good at it to being with. Given what I've described above a) do you think I'm on the right track, b) can you give me any insights or things to be careful of, and c) do you think the Harbor Freight cheapie will do the job well enough?

[HemiDog]

I assume you are talking about 1/2 square SOLID rods?
Most Mig welders around the $500 mark are only good to 1/4 inch thick metal.  If you use the hollow square tubing, you should be fine.
I personally think Mig welding is much easier than gas.  Make sure the areas that you are welding are clean of rust, grease, paint, etc...  It makes a huge difference in the ease and strength of the weld.

[mmccarty]

If that is solid 1/2" rod you are talking about a cheap mig welder isn't going to do it.  Anything over 1/4" I use an arc welder.

If you have a 240 volt service available and can wire up a receptacle I'd suggest a 240 volt unit.  Otherwise something like this will work for every once in a while hobby work:

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=91110

[tactransman]

$500 is way too much for that little project.

[ChallengerHK]

Thanks for the feedback.

If that is solid 1/2" rod you are talking about a cheap mig welder isn't going to do it.  Anything over 1/4" I use an arc welder.

I was afraid that was going to be the case. I'll check out the arc rig in your post.

$500 is way too much for that little project.

I thought so too. To be fair, the quotes I got were all around $150, to make the shape in the pic below. I also need four smallers pieces of the same basic design, but each a different aspect ratio. According to what they told me the labor wouldn't be much less for them, and the material cost is pretty close to irrelevant given the labor cost, so I'm guessing at $500-600 to have the whole thing done.

[heminut]

I assume you are talking about 1/2 square SOLID rods?
Most Mig welders around the $500 mark are only good to 1/4 inch thick metal. 

1/4"+1/4"=1/2" If he welds both sides he would be fine. Also, if you want to weld 1/2" with a smaller MIG you can V the joint and make multiple passes.