How to Make a Iron Cross Made Out of Metal

There are many types of iron, which makes welding it something of an art.

The ingredients for cast iron are as varied as Sunday dinner, and as with jewelry making, the trade is a combination of creativity and craftsmanship. Joining two pieces of cast iron can be accomplished with most gas or electric welders, but the type of electrode rod and settings for the weld must suit the type of iron being used. Be sure to check the metallurgic characteristics of your iron to ensure a lasting work of art.

Things You'll Need

• Two pieces of iron
• Acetylene torch
• Hatchet
• Forging pliers
• Welding electrode
• Welder
• Welding mask
• Welding gloves

Instructions

1. Determine the make up of the iron you plan to use. The metal's supplier can usually provide you with this information.

2. Mark the pieces of iron where they are to be cut and heat with the acetylene torch until the metal is white hot.

3. Shut off the torch and strike the hot spot repeatedly with a hatchet until cut through. While still hot, pinch the ends with the forging pliers to form a tidy end. Repeat for all four ends on the two pieces of iron. Lay one piece over the other in the desired cross pattern.

4. Select a welding electrode that will adhere to the type of iron with which you're working, and insert the metal stem into the teeth on the positive (red) lead from the welder.

5. Put on the welding mask and gloves and ground the welder. Turn on the welder and set it between 90 and 120 amps, depending on the type of iron with which you're working.

6. Touch the electrode to a corner of the joint and remove immediately. Allow the weld to cool for a few seconds and repeat the spot weld in another corner. Continue until all four corners of the cross have been welded.

Tips & Warnings

• Form any shapes on the cross before welding the two pieces. While a good weld is as strong as the metal itself, a bad or brittle weld might crack under the added tension of shaping the iron.

• Acetylene torches and welding equipment are dangerous and potentially fatal. Use extreme caution and follow all safety procedures, including wearing heat-proof gloves to protect your hands and a welding mask to prevent retinal burning.

References

• Muggy Weld: Welding Cast Iron
• Smok Stak: Welding Cast Iron