How to Weld a Pipe Joint That Is Too Wide?

Bridging welds requires slow, methodical construction of the weld.

When welding, it is sometimes necessary to produce a weld bridge because there is too much of a gap between the metal for the electrode to continue welding. This is particularly problematic when welding pipes together because there is the possibility of a leak if the pipe joint is not correctly sealed. With practice, however, you will find that bridging welds will begin to become almost second nature.

Things You'll Need

• MIG welder
• Welding helmet

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Instructions

1. Set the MIG welder for the appropriate thickness of the wall of the pipe. This information is generally noted on the cover panel of the welder or may be included in the owner's manual. Different size welders will produce different results based on the thickness of the material.

2. Attach the welder's ground clamp to one of the pipes being welded, then lower your welding shield. Turn on the welder.

3. Position the welding electrode 1/4 inch from the surface being welded at the point where the pipes come closest to meeting. Squeeze the trigger of the welder and begin to weld the pipes together.

4. Watch the weld pool begin to form through your welding helmet visor. When it has reached approximately 1/4 inch wide, begin moving the welder slowly in a crescent shape, moving the electrode from one pipe to the other with the weld pool in the middle. You will begin to see the weld pool stretch itself between the two pipes as the weld not immediately beside the electrode begins to cool.

5. Stitch the weld in this manner across the gap between the pipes, gradually filling in the gap with the melted weld electrode until you have completely filled the gap and welded the two pipes together.

Tips & Warnings

• Clean the weld slag off with a wire brush after you have completed the weld to make certain that there are no pits that may cause leaks in the pipes.

• Always wear eye protection when welding. The intense light of the welding electrode can easily damage your eyesight permanently.

References

• "Welding Complete: Techniques, Project Plans & Instructions"; Editors of CPi; 2009
• "Welder's Handbook, Revised: A Guide to Plasma Cutting, Oxyacetylene, ARC, MIG and TIG Welding"; Richard Finch; 2007
• "Welding Manual"; John Haynes; 1995