How to Weld Angle Iron

Written by c.l. rease
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How to Weld Angle Iron
MIG welding readily welds angle iron. (welding project image by leemarusa from

Angle iron provides strength and rigidity to metal projects. The thickness of angle iron reduces the amount of penetration you receive during welding. When a weld does not have proper penetration, the welded joint does not have the strength of the surrounding metal. This will cause a structural failure at the weld joint. Reducing the thickness of the angle iron at the weld joint allows the molten weld puddle to penetrate the angle iron, providing a strong connection between multiple pieces of angle.

Skill level:
Moderately Challenging

Things you need

  • 2 pair of self-locking C-grips
  • 4.5-inch grinding wheel
  • 4.5-inch angle grinder
  • MIG welder
  • Welding hood
  • Welding gloves

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  1. 1

    Set the pieces of angle iron on the corner of a nonflammable work surface. Slide one end of each angle over one end of the work surface. Clamp each piece of angle iron to the work surface with a pair of self-locking C-grips.

  2. 2

    Attach a 4.5-inch flapper wheel to the arbor of a 4.5-inch angle grinder.

  3. 3

    Bevel each of the overhanging ends of angle iron on a 30-degree angle. Stop grinding when the ends of the angle taper to a 1/16-inch thick point.

  4. 4

    Release the C-grips from the angle. Align the bevelled edges of the angles. Clamp the pieces of angle to the work surface.

  5. 5

    Turn on a MIG welder. Set the voltage and wire speed of the MIG welder to the original thickness of the angle iron. The voltage and wire speed settings are located on a placard fastened to the MIG welder.

  6. 6

    Put on a welding hood and welding gloves.

  7. 7

    Align the tip of the MIG gun with the centre of the weld joint. Lower the welding hood. Pull the trigger of the MIG gun. Move the gun in a circular motion, overlapping and filling the bevels on both pieces of angle iron. Move down 1/8 inch after each complete revolution.

  8. 8

    Allow the welded angle iron to cool for one hour before handling.

Tips and warnings

  • Wear safety glasses to avoid eye injuries while grinding the angle iron.

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