Welding football gates - best advice needed

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PaleKing

07. helmik. 2025, 15.46

Hey everyone!

I need some quick advice because things just got serious—a TV crew is coming to film at our local football field, and the last thing I want is for the goals to look like a DIY disaster on national television😅. The frame is made of 60x40mm galvanized steel tubing, and I need to weld everything properly so it’s both sturdy and presentable. But I’m running into a few issues:

1. Welds not sticking well – the zinc coating seems to mess with the adhesion, and I don’t want weak joints.
2. Overheating and warping – my welding machine sometimes heats the pipes too much, affecting their shape.
3. Cleaning before welding – I’ve been using an angle grinder, but it’s tough to remove the zinc evenly.

I want this to look solid on camera, so I could really use recommendations on which Stanley tools would help with prep and precision. Maybe a better wire brush, clamps, or a specific grinding solution? If you were in my shoes with TV cameras rolling soon, what would you use to make sure everything looks professional?

Thanks in advance—don’t want my welding skills to become the highlight of the segment for the wrong reasons! 

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  Deeris

  07. helmik. 2025, 22.35

  Hello PaleKing,

  To tackle welding issues effectively, follow these steps using Stanley tools and techniques:

  1. Welds Not Sticking Well:
     • Zinc Removal: Use a Stanley Wire Brush with stainless steel bristles to scrub off the zinc coating before welding to improve adhesion and reduce toxic fumes.
     • Grinding: For thorough removal, use a Stanley Angle Grinder with a flap disc or grinding wheel to achieve a clean, bare metal surface.
  2. Overheating and Warping:
     • Heat Control: Use a lower amperage setting and make shorter welds, allowing the metal to cool between passes to prevent overheating and warping.
     • Clamping: Use Stanley Clamps to hold pieces securely, maintaining alignment and reducing movement during welding.
  3. Cleaning Before Welding:
     • Surface Preparation: After grinding, clean the surface with a degreaser or acetone to remove contaminants for a clean weld.
     • Precision Tools: Use a Stanley Multi-Tool for fine adjustments or cleaning hard-to-reach areas.
  4. General Tips:
     • Safety First: Wear appropriate safety gear, including a welding helmet, gloves, and a respirator.
     • Practice: Practice on scrap pieces of galvanized steel to perfect your technique.

  By using the right tools and techniques, you can ensure strong, visually appealing welds for professional-looking goalposts. Good luck with the filming!

   

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  Jasbon

  08. helmik. 2025, 10.29

  1. Prep Work – Removing Zinc for Better Welds

  Zinc coating interferes with welding, so proper removal is key. Here’s what you can do:

  • Flap Discs (40-60 grit) – A Stanley flap disc on an angle grinder will remove zinc quickly while keeping a smooth surface.
  • Wire Brush (Stainless Steel) – A power wire brush (not a hand brush) helps clean up spots where grinding is difficult.
  • Stanley File Set – If needed, use a metal file for small touch-ups.

  ⚠️ Safety Note: Burning zinc releases toxic fumes (zinc oxide). Work in a well-ventilated area and wear a proper respirator (P100-rated).

  2. Welding Technique – Reducing Warping & Getting Clean Beads

  To avoid overheating and warping:

  • Use short, controlled welds – Stitch welding or short tack welds work best. Let the metal cool between passes.
  • Clamp the frame securely – Stanley heavy-duty clamps will hold parts in place to prevent movement during welding.
  • Use the right amperage – Too much heat causes warping. If using MIG welding, try C25 gas (75% argon, 25% CO2) for clean welds.

  3. Finishing Touches – Making It Look TV-Ready

  • Grinding & Smoothing: A Stanley grinding disc or flap disc can clean up welds without gouging the metal.
  • Primer & Paint: After welding, use cold galvanizing spray to restore protection and follow up with a high-quality paint.

  Bonus Tip: Hidden Welds for a Clean Look

  If possible, weld on the backside of the frame where it's less visible. A good Stanley square and level will also help ensure everything is straight and aligned perfectly.

  With these steps, your football gates will look strong and camera-ready. Hope it turns out great—good luck with the TV shoot! 🎥💪🔥

   

  4o

   

   

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