Quote Originally Posted by performance View Post
Keep your torch head constantly moving to match the angle of the tubing. Small diameter tubing means you have to stay on top of things. Don't hold the torch till your hand cramps. Holding it light and easy will help keep things going and smooth.
Yeah... small round bar like that has to be done steady, quick, and light. There isn't a whole lot of heat, or filler rod that is going into the weld.
If you're having problems with your welds just being gobbed up at the joint, you are probably using too much filler rod. I would use 1/16" rod, and not very much of it at that. Most of the welding will be done with just the torch, and only a small amount of filler so that the weld isn't undercut.
If your weld just looks nasty, then you may need to clean the metals. Small diameter hot rolled bar is notorious for having contaminants from the mills and dealers. Make sure you take a grinder to the area that you are welding to make sure it is absolutely clean and you see shiny metal all around. Otherwise, you may pick up some of the 'pickle' solution that they dip the metals in at the mill to keep them from rusting.