Spot welding mesh to SHS frame

[SamDavis]

Whilst checking out a friends new professionally built aviary I noticed the mesh had been spot welded to the SHS frame. It really looked neat - much better than tek or other types of screws. It also means both sides of the frame have a flat surface so the design in terms of bolting frames together is simplified.

Has anyone done this 'spot welding' and if so could you provide details of the tool/method used.

[Brooksy]

How heavy was the mesh?

[gomer]

I would think you would need .8 welding wire and a very low setting on your welder.how would you hold it taught while welding ?maybe put a screw in and take it out again.Next time your around could you grab a photo to share Sam ?

[Craig52]

IMO,once the wire is hit with the weld it would lose all it's weather protection and corrosion will be a major concern with outside aviaries but would be ok for indoor cages etc Craig

[SamDavis]

This was heavy half inch mesh (maybe 1.2mm or even 1.6mm), was outside and from memory I think it had been sprayed with cold gal or similar paint. Certainly had no extra metal added so I'm sure it was a spot weld process where the wire in the mesh itself was melted to the SHS. Gomer- I'd say it would be brilliant for your current build (assuming a simple process).
I have photos on my phone but not sure if they're detailed enough to show the welds. I'll have a look when and if I can just find my phone!

[gomer]

I have seen sheet wire welded but not rolled wire.Even with the sheet wire with the .9 spool it is very difficult to weld Maybe the .8 spool it would be easier.As croc said I would be concerned with breaking the integrity of the wire.Even welding the rhs and cold galing it after a few years you see the odd bit of rust. Still a interesting concept though and would be intersting to see the finshed product now and in 5 to 10 years.

[SamDavis]

Here's a pic...

spotweld.jpg

The welds are not really clear but shows the finish. The owner of the aviary is a member of AFF but by his own admission he "doesn't do DIY" - I suspect changing a light globe may even be beyond him! Nevertheless I'll try to get him to take some close ups of the welds and post.

[COUNTRY CAPITAL]

i like the idea too sam....nice neat finish.
how do you see the birds through wire that thick though??? reminds me of gaol....or a parrot cage.
are you going to reveal the aff member who can't change that lightbulb....? might be a few of us ducking for cover.

[casehulsebosch]

Painting the wire black goes a long way towards seeing and enjoying the birds better.

Cheers, Case, NT

[Bmac27]

Sam ,
From a Boiler maker/welders perspective , IMO , I would advise against this method in general .
Whilst the finished product may look desirable , its durability comes into question ... the mesh at the Immediate site of the spot weld becomes brittle and is susceptible to cracking even mesh up to 4mm will crack over time ... rust is also a factor even when painted with galv .
Small impacts can lead to multiple cracks at weld sites along the frame ... and this could lead to escapees.
I would advise your friend to maybe beef up the mesh by adding angle iron to the outside of the existing frame and sandwiching the wire in between , this can then be spot welded into place and cleaned to look quite neat .
Brad