How To Weld Thin Metal: A Beginners Guide

Did you know that welding is the process of fusing materials together by heating them with a special torch until they combine into a single solid piece? Welding is an excellent skill to possess, especially if you work in a trade or other field that requires manual labor. It can be utilized in almost any job — from construction to manufacturing, plumbing, auto repair and so much more! However, not everyone is capable of learning how to weld. Many people find it difficult to grasp the techniques involved because it requires a certain level of concentration and hand-eye coordination. Working with thin metal comes with its own set of challenges. Most welding techniques require working with pieces that are at least 1/16 inch thick or greater; however, some may need to be thinner than that. Here is everything you need to know about how to weld thin metal so you can tackle those projects with confidence!

How To Weld Thin Metal

1. Prepare The Metal

The first step to welding thin metal is making sure you have the proper tools and equipment. You’ll need a welder, a cutting torch, and an anvil. The anvil is used to support the welded piece and protect it from being broken during welding. It also acts as a heat sink, which helps to keep the piece at a more consistent temperature. To use your welder, you will need to plug it in and select the appropriate settings.

2. Apply Fluxes

Once you have your equipment ready, you can begin working on your project! First, apply fluxes to both pieces of metal (thin or thick) that you intend on welding together using either an acid mixture or a solvent-based solution. Fluxes are substances that help prevent rust as well as make your welds stronger for longer periods of time than if they were not applied at all. Many fluxes contain metals such as tin and manganese, which are used to enhance welds.

3. Weld Thin Metal

Now that you have applied the fluxes, it is time to weld! To begin, you will need to select a spot on the anvil where you will be placing the thick piece of metal. You can start by heating your torch and holding it close to the end of your thin piece of metal. Apply as much heat as possible while maintaining a steady pace as you slowly move the torch back and forth along the length of the piece. Your goal is to melt both pieces together, but this will take some practice! Once they are melted, hold them in place using anvils or clamps and slowly move them over onto your work table. Then, remove any residual flux that may remain on your work surface with a rag or brush before proceeding with your next step.

4. Weld Thin Metal

Next, you will need to weld together two pieces of thicker metal using either a MIG or TIG welder. Welding thicker pieces of metal will require more heat and consequently more time. The thicker the piece of metal being welded, the stronger your welds will be.

5. Clean Up

After you have completed welding thin metal, you will need to clean up both pieces to ensure that they are free from any residual flux that may remain on them. This may take some time to complete, so keep an eye on your work area, and don’t forget to clean it up as you go along!

6. Make A Patch

If you are working with a piece of metal that is too thick to be welded together, you can create a patch by cutting the piece in half and then welding it back together again. To do this, first cut the metal in half. Then, use your torch to weld the two halves together so that they are now one piece of metal. Once this has been completed, use a grinder or an angle grinder to grind down the edges of your welder’s welds. This will ensure that there are no sharp edges on your patch and that it will be able to fit into place without any issues!

Guide To Welding Thin Metal

1. Goggles/Safety Glasses

If you are going to work with a thin metal, it is crucial that you wear safety glasses or goggles. The welding fumes can cause eye damage if inhaled, so this is a must! While it may seem like a small detail, it is an important one to take note of. Make sure your glasses fit the way you want them to before starting. If they are too tight, they will cause discomfort and make focusing more difficult. It’s best to err on the side of caution and get the right size.

2. Safety Glasses/Goggles

You will also need safety glasses/goggles for when you start this project! You should not use any other glasses when welding or any other type of metal work because they may contain dangerous chemicals that can hurt your eyes if they come into contact with them. There are some other types of goggles that are great for welding as well because they shield your entire face from hot metal. This makes it easier to focus and prevents anything from getting into your eyes.

3. Welding Gloves

Welding gloves are another essential item that you will need for welding with thin metal. They are designed to protect your hands from the heat that is produced when welding with thin metals because it is quite high. You should not wear any other types of gloves while working with these materials because they will not provide adequate protection.

4. Welding Gloves, Colors, And Sizes

You may have different needs when it comes to the welding gloves you choose to use, so it’s important to think about them before making your purchase decision. You may want a pair that is made out of leather or a more durable material so they last longer and resist tearing or cracking over time. You can also choose between having different colors, such as black or blue, so you can match them to whatever project you are working on at the time. The size of your gloves is also important. You may want a pair that will fit perfectly because you’re going to want to be able to move your hands freely while welding.

Tapping And Scraping During Welding

1. Tapping

Tapping is the process of removing metal from a piece by hitting it with a chisel or similar tool. It is done to create a “weld-off” in which the two pieces are welded together. When working with thinner metals, you need to be extremely careful when tapping them. You must use a chisel that is specifically designed for the job and it must be sharpened beforehand. If you don’t have a chisel that is sharp enough, you could easily chip out the metal or even hurt your hand! To tap your piece, place some masking tape on top of it, then use your chisel to hammer down along the edge of the tape until it begins to chip off. Once this happens, remove the tape and put on another piece of masking tape with an outline around where you want your weld line to be. Then tap again along the edge of this new piece until you get an even weld-off line.

2. Scraping

Scraping is similar to tapping in that it is also used to create a weld-off in which the two pieces are welded together. However, scrapers are designed specifically to remove metal so they can be used on thin metals. They must be sharpened beforehand, just like chisels. To scrape your piece, place the scrapers on top of it and use the back of your hand to tap along the edge of them until you get an even weld-off line.

3. Flux Penetration And Reflow

Flux is a substance that helps metal become more conductive so it can be welded together more effectively. It does this by having a chemical reaction with the metal and forms a layer that bonds with it this layer prevents oxygen from getting into the metal, which means there can’t be any oxidation (rust) or hydrogen gas generated during welding! The most common fluxes are TIG welding flux, which is used by TIG welders, and MIG welding flux which is used by MIG welders. To use flux, you will need to pre-melt it before using it on your piece. This pre-melting process can be done by heating the metal until the flux melts and then pouring it over the metal. Then you can do a normal weld using the same technique that you would use if you were using regular welding flux.

Tips For Welding Thin Metal

1. Use A Minimum Of Power

When welding thin metal, it is important to use the least amount of power necessary. It can be difficult to get a good weld if you try to apply too much heat or force. You may even damage the metal! Be sure to use only enough power needed for the job at hand; otherwise, you could end up damaging the piece you are trying to weld.

2. Keep Your Hands Steady And Your Movements Slow

One of the biggest challenges when working with thin metal is keeping your hands steady and your movements slow. The torch may not be hot enough if you are moving too quickly or not holding it correctly. To avoid this, take your time and keep yourself relaxed while performing the task at hand. Remember that this is a skill that takes practice! Practice makes perfect!

3. Make Sure To Clean All Dirt Off Before Starting Welding

It is crucial that all dirt and debris are removed from the piece before starting welding so that you can get a clean weld. If there is any dirt on the piece, it will not flow into the welding torch and will result in a poor weld. Also, if you have any rust or other metals on the piece, they can interfere with the process and cause problems.

4. Remember To Always Keep Your Hands Away From The Metal While Welding

When welding thin metal, it is important to keep your hands at least 6 inches away from the piece while working with a torch. This is to avoid getting burned by the flame or melting any pieces of metal that are attached to your hand.

5. Use Short Bursts Of Heat Over Time To Prevent Overheating

When welding thin metal, you should apply short bursts of heat over time in order to prevent overheating and distortion of the metal being worked on. You should only apply heat for around 30 seconds at a time; however, if you use too much heat for too long it may cause distortion and damage to the piece.


Thin metal welding can be tricky, but it is not impossible! With the right tools, skills, and knowledge, you can successfully weld thin metal. It is important to remember that when working with a thin metal, you have to have a slower pace and use a lower amount of heat. If you are struggling with welding thin metal, remember that you are not alone! It is a challenge many people face. Start with a few smaller projects. Once you master the basics, you can move on to more difficult projects.

Felix Hiett
Felix Hiett
Felix Hiett is a welding expert blogger who writes about welding and other related topics. He is also an experienced welder and has worked on a variety of projects.