Eastwood 20636 User manual

MIG STUD WELD KIT
INSTRUCTIONS
Part #20636

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The EASTWOOD MIG STUD WELDING KIT transforms your MIG welder into a Stud Welder
which can be used to repair and remove dents from sheet metal.
CONTENTS
The following items should be included with your Eastwood MIG Stud Welding Kit
(1) Stud Welding Nozzle
(1) Slide Hammer
(1) 2mm Hex Key
(100) 2mm Pins
SAFETY INFORMATION
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION used with the safety alert symbol, indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
READ INSTRUCTIONS
Read all manuals included with specific MIG welders used during the
stud welding process. Be aware of all welder safety warnings.

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ELECTRIC SHOCK HAZARD!
• Improper use of an electric welder can cause electric shock, injury and
death! Read all precautions described in the Welder Manual to reduce
the possibility of electric shock.
• Disconnect welder from power supply before assembly, disassembly or
maintenance of the torch, contact tip and when installing or removing
the Stud Welding Nozzle.
• Always wear dry, protective clothing and leather welding gloves and
insulated footwear. Use suitable clothing made from durable flame-resistant
material to protect your skin.
• If other persons or pets are in the area of welding, use welding screens to
protect bystanders from sparks.
• Always operate the welder in a clean, dry, well ventilated area.
Do not operate the welder in humid, wet, rainy or poorly ventilated areas.
• The electrode and work (or ground) circuits are electrically “hot” when the
welder is on. Do not allow these “hot” parts to come in contact with your
bare skin or wet clothing.
• Separate yourself from the welding circuit by using insulating mats to
prevent contact from the work surface.
• Be sure that the work piece is properly supported and grounded prior to
beginning an electric welding operation.
• Always attach the ground clamp to the piece to be welded and as close to
the weld area as possible. This will give the least resistance and best weld.
FIRE AND EXPLOSION HAZARD!
• Electric welding produces sparks which can be discharged considerable
distances at high velocity igniting flammable or exploding vapors
and materials.
• Do not operate electric arc welder in areas where flammable or explosive
vapors are present.
• Do not use near combustible surfaces. Remove all flammable items
within 35 feet of the welding area.
• Always keep a fire extinguisher nearby while welding.
• Use welding blankets to protect painted and or flammable surfaces;
rubber weather-stripping, dash boards, engines, etc.
• Ensure power supply has properly rated wiring to handle power usage.
SAFETY INFORMATION

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BURN HAZARD!
• Electric welding heats metal and tools to temperatures that will cause
severe burns!
• Use protective, heat resistant gloves and clothing when using the Eastwood
MIG Stud Welding Kit. Never touch work surface or Stud Welding Nozzle
until it they have completely cooled.
ELECTROMAGNETIC HAZARD!
• The electromagnetic field that is generated during arc welding may interfere
with various electrical and electronic devices such as cardiac pacemak-
ers. Anyone using such devices should consult with their physician prior to
performing any electric welding operations.
• Exposure to electromagnetic fields while welding may have other health
effects which are not known.
FUMES AND GASES HAZARD!
• Fumes and gasses released during welding are hazardous. Do not breathe
fumes that are produced by the welding operation. Wear an OSHA-approved
respirator when welding.
• Always work in a properly ventilated area.
• Never weld coated materials including, but not limited to: cadmium plated,
galvanized, lead based paints.
ARC RAY HAZARD!
• Arc rays produce intense ultraviolet radiation which can burn exposed flesh
and cause eye damage. Use a shield with the proper filter (a minimum
of #11) to protect your eyes from sparks and the rays of the arc when
welding or when observing open arc welding (see ANSI Z49.1 and Z87.1
for safety standards).
• Use suitable clothing made from durable flame-resistant material to
protect your skin.
• If other persons or pets are in the area of welding, use welding screens
to protect bystanders from sparks and arc rays.

FLYING CHIPS HAZARD!
• Grinding and sanding will eject metal chips, dust, debris and sparks at high
velocity. To prevent eye injury wear approved safety glasses.
• Wear an OSHA-approved respirator when grinding or sanding.
• Read all manuals included with specific grinders, sanders or other power
tools used before and after the Stud Welding process. Be aware of all
power tool safety warnings.
PINCH HAZARD!
• Operating the Slide Hammer exerts considerable striking force in use,
which can quickly pinch fingers and hands. Grip and operate tool only
by the hand-grip areas to avoid pinching.
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SET UP
To utilize your Eastwood MIG Stud Welder Kit, you will need a MIG welder with a minimum of
100 Amp output that utilizes a Tweco style nozzle.
NOTE: This was designed for Tweco-Style torches, but may work on other styles.
1. Loosen the set screws on the body
of the Eastwood Stud Welding
Nozzle and slide it over your gas
nozzle. The Pin Holder Branch of
the Eastwood Stud Welding Nozzle
should be oriented as shown in
(FIG 1).
2. Tighten the two set screws, with
the included 2mm Hex Key, once
the Stud Nozzle has been put in
place but keep in mind that it may
require adjustments when getting
started for optimum results.
SHOCK HAZARD!
All the following steps MUST be completed with the welder turned off
and uplugged.
FIG. 1
FIG. 1
Stud Weld Nozzle
Set Screws
Pin Holder Branch
Set Screw

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OPERATION
Several adjustments need to be made to optimize the Eastwood MIG Stud Nozzle before it will
operate properly. They are:
• Depth of MIG Gas Nozzle into the Stud Welding Nozzle.
• Set Screw Depth of Pin Holder Branch.
• Volt Setting on MIG Welder.
• Wire Speed Setting on MIG Welder.
The following wire speed chart displays starting point settings for the Eastwood MIG135, MIG175 and
MIG250 welders using 0.030 wire. NOTE: These settings can vary based on electrical input, specific
welding situation, ambient temperature, material cleanliness, and material thickness:
Once the Stud Welding Nozzle has been installed onto your torch and adjusted for proper use, the stud
welding process can begin:
WELDER MIG135 MIG175 MIG250
Arc Volts ID23
Wire Speed 64260
1. Insert a Pin into the Pin Holder Branch of
the Stud Welding Nozzle and place the
torch on a flat surface as shown in (FIG 2).
2.
Adjust the Set Screw, with the included
2mm Hex Key, in the end of the smaller
diameter Pin Holder Branch of the Eastwood
Stud Welding Nozzle so that when it is rest-
ing at a 45° angle to the work surface as
shown in (FIG 2), the pin is making contact
with the work surface as well as the set
screw in the Pin Holder Branch.
NOTE: If desired a magnet can be wiped
across the surface of the Pin Holder Branch
of the Stud Welding Nozzle magnetizing it to
aid in retaining the Pins while positioning.
FIG. 2
FIG. 2
Set Screw
Set Screw
Pin
Work Surface

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WELDING ON PINS
1. Remove paint and any other coatings from the damaged area.
2. Insert Pin into the Pin Holder Branch of the Pin Holder Branch.
3. Place the 45° angled surface of the Stud Welding Nozzle against the panel with the Pin Holder
Branch perpendicular to the working surface.
4. Hold the trigger down for ~2 seconds or until the head of the Pin is securely fused to the panel.
Note: The weld bead does not need to be centered on the Pin, just securely attached to the
work surface metal.
5. If the pin is not properly welded to the panel, it will easily be pulled off by the slide hammer.
6. Hold the Stud Welding Nozzle on the pin for a minimum of 3 seconds after the arc has stopped
to allow the weld puddle to cool before lifting the torch.
7. Weld on as many studs as required to pull the dent.
PULLING THE PINS
1. Apply the Slide hammer by slipping the open Collet on the Slide Hammer over the Pin.
2. Tighten the Collet of the Slide Hammer on the Pin by rotating the hex section until it grips
the Pin. It can quickly be released by rotating the hex in the opposite direction.
3. Use a sharp, solid, outward pull on the Sliding Weight of the Slide Hammer allowing it to stop
against the Hand Grip to pull the dent. Some dents will require more force than others.
4. Repeat Slide Hammer process on all of the pins in the damaged area.
BURN HAZARD!
Use protective, heat-resistant gloves and clothing when using the Eastwood
MIG Stud Welding Kit. Never touch work surface or Stud Welding Nozzle until
they have completely cooled.
PINCH HAZARD!
Keep hands and fingers out from between moving components of the Slide
Hammer. Keep hands firmly on the Hand Grip sections of the tool only.

REMOVING THE PINS
1. Once the dent has been successfully ‘pulled’, the Pins need to be removed from the surface.
The pins can be cut off near the heads and ground down using a DA Sander or Flap Disc on a
Grinder. Do not allow the metal to get too hot when grinding or it could warp the panel.
APPLICATION
Stud welding is a method used for removing dents in sheet metal with advantages that really stand
out when using on panels where it is not possible to get to the backside with a hammer and dolly. As
with many other sheet metal repair tasks it will take some practice to acquire the skill to master the
Slide Hammer technique. NOTE: To avoid further damage on a project, It is strongly recommended to
practice on scrap metal or damaged salvage yard parts before using on your project. To remove a dent
you can follow the following basic steps:
1. Identify where the dent is located on the panel.
2. Use either a grinder with a flap disc or a DA Sander with 40 Grit paper to remove all of the
paint. If there are deep areas with a disc cannot get into, use a wire brush on an angle grinder
or drill.
3. Once all of the paint is removed, locate the lowest spots of the dent and start by adding pins to
these locations.
4. Apply the Slide hammer by slipping the open Collet on the Slide Hammer over the Pin.
5. Tighten the Collet of the Slide Hammer on the Pin by rotating the hex section until it grips the
Pin. It can quickly be released by rotating the hex in the opposite direction.
6. Use a sharp, solid, outward pull on the Sliding Weight of the Slide Hammer allowing it to stop
against the Hand Grip to pull the dent. Some dents will require more force than others.
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PINCH HAZARD!
Keep hands and fingers out from between moving components of the Slide
Hammer. Keep hands firmly on the Hand Grip sections of the tool only.
FLYING METAL CHIP HAZARD!
Grinding and sanding will eject metal chips, dust, debris and sparks at high
velocity. To prevent eye injury wear approved safety glasses. Wear an OSHA-
approved respirator when grinding or sanding. Read all manuals included with
specific grinders, sanders or other power tools used before and after the Stud
Welding process. Be aware of all power tool safety warnings.

1. Expand out and add more pins to the areas that are not as deep. These shallow areas will
require fewer pins be welded.
2. Allow the metal to cool to keep from pulling the pins off the panel.
3. When choosing which pins to pull you should start at the outside of the dent and work towards
the center. Ideally the dent should be repaired enough so that the maximum amount of filler
used should be 1/16” or less.
4. If the dent is still not sufficiently removed, re-apply pins and pull the dent more.
5. Once the dent has been repaired, the pins can be cut off near the heads and ground down
using a DA Sander or Flap Disc on a Grinder. Do not allow the metal to get to hot when
grinding or it could warp the panel.
6. Properly clean the surface and apply body filler as necessary followed by primer and a top coat.
To order parts and supplies: 800.345.1178 >> eastwood.com 9
FLYING METAL CHIP HAZARD!
Grinding and sanding will eject metal chips, dust, debris and sparks at high
velocity. To prevent eye injury wear approved safety glasses. Wear an OSHA-
approved respirator when grinding or sanding. Read all manuals included with
specific grinders, sanders or other power tools used before and after the Stud
Welding process. Be aware of all power tool safety warnings.

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PROBLEM CAUSE CORRECTION
When Using
Slide Hammer,
the Pin Pulls
Off the Panel
Pin is not
completely
fused
Make adjustments to the welder and/or the
position of the Stud Weld Nozzle.
Contaminated
Base Metal
Make sure the panel is free of dirt, grease, paint,
wax, etc.
Slide Hammer
Slips Off
Pin When
Operating
Gripping Collet
may be clogged
Unthread and remove the hex section of the
Slide Hammer, remove Collet and clean it out.
When Lifting
the Torch Off
the Piece after
Welding, the
Pin Lifts Up
with It.
Weld puddle
too hot
Allow weld puddle to cool before lifting the
Torch off of the Pin.
Excessive
Weld Bead
Needed to Get
Pin to Fuse to
Panel
Stud Weld
Nozzle not
aligned
correctly
Adjust the Stud Weld Nozzle so that the wire is
in direct contact with the head of the Pin.
TROUBLE SHOOTING