How to Weld a Metal Bar to a Metal Pole

Welded yard art

Your yard sculpture or landscape addition is almost complete, except for one last thing. You need to weld a metal bar to a metal pole. Your best bet is to weld a fillet joint, which attaches two items together by beading around the area where they meet. Your bar and pole can be attached at any angle, as long as you use the proper angle with the welding tip to get the results you want.

Things You'll Need

• Coarse sandpaper or grinder with sanding tip
• Hose and rag
• Welder
• Clamps

Instructions

1. Clean and sand your items. Hose and wipe down both the metal bar and pole to remove any dirt. Use sandpaper or a sanding tip on a grinder to remove paint, rust or other any other finish or debris from the areas you need welded together.

2. Position the items how you want them welded together. Arrange the items next to each other, double-checking that both the end of the pole and the pipe area where you will be welding are stripped down to bare metal.

3. Secure the items in place. Use clamps to firmly attach the bar to the pole so they remain immobile during the welding process.

4. Weld. Place the welder's clamp as close as possible to the area you are welding. Hold the welding tip at a 45-degree angle, and move it slowly around the circumference of the bar where you want it to attach to the pole. Adjust the feed speed and temperature to match the thickness of the metal. Lower both if you are making unwanted holes in the pole. Increase both if you are not outputting enough for the metal bar to stick.