1. The first step of a successful weld is grinding the surface clean of any paint or debris and grinding a spot for the ground clamp to attach (a clean surface is a must for MIG welding).
2. With a 60-grit flap disk, I cleaned the surface of a gusset and grinded a bevel on the edge of the mating surface, which lets the weld penetrate better making it stronger.
3. You can see the bevel ground onto both sides of the mating surface.
4. I try to keep my ground clamp close to my welding location; electricity takes the path of least resistance—this reduces your chances of getting zapped.
5. A mix of 75/25 gas (75-percent Argon and 25-percent C02 is the best shielding gas for welding mild steel). For indoor, I use 15-20 psi and 23-30 psi outdoors.
6. Tack welding is a very important step. I tack weld everything before finish welding. This prevents anything for moving or bending while welding.
7. Now on to welding this 3/16-inch gusset with a 10-degree angle on the torch and a 3/8-inch work depth (how far the wire sticks out) using circular motions covering both sides evenly dragging it parallel.
8. Finished weld should be even and have a somewhat flat look to it like a stack of dimes and not a raised stringy look.