Welder - work in progress

Please note, this is a work in progress. Please do not use the welder until inducted - thanks, Ollie

Prior to using the welder, you must attend an in-person induction. Please post on the forum if you want an induction. Should be starting spring 2025

Prior to an induction, please have a quick read through the welder manual, and read this wiki page.

Induction notes are here -

Please note, the induction only covers the basics and essential safety elements, as well as any hackspace-specific rules. There won't be anything on welding techniques / settings, as there's a myriad of information online.

• Before commencing any welding, ensure the hot works area is clear from flammable items. Do not weld if there are strong, potentially flammable fumes in the space
• Do not weld items which could be flammable. No not weld vehicles
• Do not weld items which contain surface finishes, which could release flammable or hazardous fumes such as painted or galvanised surfaces.
• Keeping workpieces clean can help to minimise sparks and will result in a better weld
• Make yourself aware of firefighting equipment in the space (e.g., fire extinguishers, just outside of the hot works area. Familiarise yourself with where they are, and how you would operate them.
• Have a bucket of sand next to the welding bench, which can quickly and safely extinguish minor flames with minimal cleanup
• The roller shutter doors must remain open during welding operations, and kept open until fumes have cleared
• Fume extraction must be used at all times, and kept on until fumes have cleared. Check fume extractor has not been used for general extraction or hoovering - open the top and ensure there are no flammable items inside (eg sawdust)
• After welding, you MUST remain in the space for at least 1 hour, checking the area for smouldering items or fires. If you cannot wait the hour, do not weld

• Welded parts will be hot, but heat can be minimised by welding intermittently, with short welds. Quench as required, but being careful of steam release.
• Wear appropriate welding gloves / gauntlets. Check their condition before welding. The Hackspace has gloves, but you may wish to bring your own
• Ensure you are sufficiently protected from sparks. Cotton (or other appropriate fireproof material) overalls or a top made from fireproof, burn resistant material with long sleeves should be worn. Such PPE is provided, and will be pointed out in the induction
• It is possible to get sunburn from welding, from the emitted UV light. You must wear a welding hood or use an appropriate visor.
• Make care when handling welded items, or torch components. Even with gauntlets there is a potential for burns
• Think about other members – don’t leave hot items lying around.

• Position the mobile welding guard such that it completely shields all uninvolved parties from arcing. This includes, but not limited to, members of public outside the hackspace, hackspace members and road users.
• Do not attempt to remove, prop up, or otherwise overcome the fixed welding curtain.
• Appropriate welding masks/shields/goggles must be used by all parties within the hot works area
• Prior to welding, with the isolator switch turned on, ensure the beacon lights are flashing. These warn other users that welding is being carried out

• Check the condition of cables and insulators before turning on the welder
• Avoid welding in high humidity. Wet clothing, floors, and workpieces increase the risk of electric shocks.
• Do not attempt to bypass electrical safety equipment, and keep welder covers closed during welding
• If you have a pacemaker (etc), and only proceed if you've confirmed with your doctor that it’s safe to weld.

The following PPE must be used

• Gauntlets
• Fire-proof long sleeve clothing (e.g. overalls)
• Welding hood or mask. There are three hanging up, just outside the hot works area. Link to manual https://www.clarkeservice.co.uk/manuals/welding_accessories/PG4_Headshield_Iss_3.pdf
• Closed footwear

These are the minimum requirements. You may also need additional PPE for other related tasks, such as eye protection when using an angle grinder.

The welder is stored on the lower shelf of the welding table, in the hot works area, next to the roller shutter doors. Also on the table are a few welding accessories such as a pair of MIG pliers and a chipping hammer

The Hackspace welder is a Clarke MIG160EN, with an adjustable welding current between 30 and 150 Amps. This is enough to weld 5mm mild steel, and to blow holes through thinner stuff.

Link to manual - https://www.clarkeservice.co.uk/manuals/mig_welders/MIG160EN_Mig_Welder_REV_8.pdf

The fume extractor is an Extractability Protectavac by Weldability. It must be used at all times during welding, to help keep fume levels low Link to product page - https://www.weldability-sif.com/products/extractability/ext1vacmax230/

[photos to be added here at a later date, to show instructions for operation and maintenance]

The welder is designed for both gas MIG and Gasless welding, however in the Hackspace all welding shall be the gasless type. This uses wire with a flux core to prevent oxidisation and contamination of the weld pool. Whilst the welder can operate as a standard MIG (ie with Gas) the Hackspace does permit compressed cylinders. The risk assessment for the welding has not considered the use of shielding gas, so for the foreseeable, all welding shall be gasless