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    JMperformance Badlands buggy ST3 thread
    #1
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    This is going to be a thread for my current project, a badlands buggy st3. I am putting a 2001 gsxr 600 motor in this buggy. i listid a picture of it below.


    My first question is: I have a HD power systems 120v MiG and flux core welder. I have not used the MiG option yet but I have used the flux. Would this welder be good enough to redo some of the welds on the frame? I have already used the flux core on some thick steel and it had absolutely awesome penetration, the steel was glowing red hot from the other side. please let me know!

    Here is the link to the welder: Welders & Cutters - HD Power Systems, Inc.HD Power Systems, Inc.
    light up badlands buggy st3.jpg
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    Re: JMperformance Badlands buggy ST3 thread
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    You may want to fact check this, but I have read on Race-dezert forums that flux core is more prone to cracking when used in off road fabrication due to the sudden jerking and shock forces on the chassis. I would think mig would have less weld contamination and less places in the weld for cracks to form due to the shielding properties of the gas.
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    Re: JMperformance Badlands buggy ST3 thread
    #3
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    Quote Originally Posted by aschn View Post
    You may want to fact check this, but I have read on Race-dezert forums that flux core is more prone to cracking when used in off road fabrication due to the sudden jerking and shock forces on the chassis. I would think mig would have less weld contamination and less places in the weld for cracks to form due to the shielding properties of the gas.

    Do you think that the 120v MiG would be enough? from what I've tried it works great.
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    Re: JMperformance Badlands buggy ST3 thread
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    If your serious about a cage, don't weld it with Flux Core wire. Get some gas. If your welder doesn't support gas (like mine) get rid of it. Yet another reason I haven't been fabricating so much lately. Flux Core is not as preferred.
    HARD WORK PAY$
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    Re: JMperformance Badlands buggy ST3 thread
    #5
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    Quote Originally Posted by 67StingrayJ View Post
    If your serious about a cage, don't weld it with Flux Core wire. Get some gas. If your welder doesn't support gas (like mine) get rid of it. Yet another reason I haven't been fabricating so much lately. Flux Core is not as preferred.
    The welder I have does support gas. Do you think that the 120v will be enough? It does not have the option to do 240v.
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    Re: JMperformance Badlands buggy ST3 thread
    #6
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    flip the lid and look at what the welder will do. Mine said it would do 1/4" thick material. But I welded thicker too. A lot of it depends on what you can do with that welder. 120v could be plenty. Question is, can you be a steady enough hand to get the penetration your after? If you prep the weld area properly you can achieve some really great things with a wimpy welder. But yes, 120v should be plenty.
    HARD WORK PAY$
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    Re: JMperformance Badlands buggy ST3 thread
    #7
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    Quote Originally Posted by 67StingrayJ View Post
    flip the lid and look at what the welder will do. Mine said it would do 1/4" thick material. But I welded thicker too. A lot of it depends on what you can do with that welder. 120v could be plenty. Question is, can you be a steady enough hand to get the penetration your after? If you prep the weld area properly you can achieve some really great things with a wimpy welder. But yes, 120v should be plenty.
    Ok I will look on the welder tonight. Thanks for the advice!
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    Re: JMperformance Badlands buggy ST3 thread
    #8
    The Wizard of Welding kustomfab2003's Avatar
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    Since I work for a major welding Mfg company I will try and give you the low down on some of your questions.

    1. 120V Welder - Doesn't really tell much because that is the input power. Since inverter technology has come a long way what we need to know is what is the rated amperage? and what is the duty cycle of that amperage? Duty cycle is a percentage that you can operate the machine at it's rated amperage for a time period. So, a 20% duty cycle at 140amps would mean that you could weld typically for 2 minutes non-stop before they machine would start to reach it's thermal cycle (overheat) and shut down.

    2. Flux core vs MIG... Both are the same basic wire feed machine, but one uses a flux cored wire with a polarity of DC electrode negative and leaves a slag behind and MIG (metal inert gas actually GMAW Gas Metal Arc Welding) will use a solid 70s-6 (70,000 psi tensile strength) and then be shielded with a CO2 or Argon/CO2 blend. Most common is 75ar/25co2.

    3. Strength and cracking of the wire... flux cored products have some along way and most of the cracking seen were people using the wrong product and then running multi-pass welds with it when it was only rated for a single pass. Multi-pass welding begins to dilute the parent metal and weld metal mechanicals thus making a weaker, more crack sensitive weld.

    Please feel free to post a direct link to your welder as the link you posted was to their site and not a specific product. I/we will help as much as possible.

    -Josh
    Marine Veteran Sgt USMC 8151/8541 1992-2000
    Process Improvement Specialist Miller Electric MFG LLC
    CWI CWS CWE
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    Re: JMperformance Badlands buggy ST3 thread
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    Since the motor is only a 600 and I have to have the correct gear ratio. Would a 60 tooth rear sprocket and a 16 tooth front sprocket be a good gear ratio for 90-100hp and 1000lbs?
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    Re: JMperformance Badlands buggy ST3 thread
    #10
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    Quote Originally Posted by kustomfab2003 View Post
    Since I work for a major welding Mfg company I will try and give you the low down on some of your questions.

    1. 120V Welder - Doesn't really tell much because that is the input power. Since inverter technology has come a long way what we need to know is what is the rated amperage? and what is the duty cycle of that amperage? Duty cycle is a percentage that you can operate the machine at it's rated amperage for a time period. So, a 20% duty cycle at 140amps would mean that you could weld typically for 2 minutes non-stop before they machine would start to reach it's thermal cycle (overheat) and shut down.

    2. Flux core vs MIG... Both are the same basic wire feed machine, but one uses a flux cored wire with a polarity of DC electrode negative and leaves a slag behind and MIG (metal inert gas actually GMAW Gas Metal Arc Welding) will use a solid 70s-6 (70,000 psi tensile strength) and then be shielded with a CO2 or Argon/CO2 blend. Most common is 75ar/25co2.

    3. Strength and cracking of the wire... flux cored products have some along way and most of the cracking seen were people using the wrong product and then running multi-pass welds with it when it was only rated for a single pass. Multi-pass welding begins to dilute the parent metal and weld metal mechanicals thus making a weaker, more crack sensitive weld.

    Please feel free to post a direct link to your welder as the link you posted was to their site and not a specific product. I/we will help as much as possible.

    -Josh
    turns out the welder I have is made by a company called wolf welders and HD power systems is just a branding thing.

    here is a YouTube video that displays the welder I have: Wolf Combination Gas / No Gas MIG 140 Welder - YouTube


    I just got the correct fittings for the regulator I have to my welder. I could not find the duty cycle or the max rated metal thickness so I emailed heavy duty power systems.

    here is the link to the user Manuel for my welder: ˵USER'S MANUAL.cdr (hdpowersystems.com)
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