Ok, so explain this to the guy who got kicked out of metal work in the first week for making shuriken...
You're blobbing a bunch of weld on and then filing it to the correct shape once it hardens?
Yeah essentially. You could possibly run a continuous bead but I was afraid of burning through and I'm much too in-experienced to know the proper settings; so I ran a series of overlapping tacks (pulled the trigger for about 2 secs).
The second picture I just posted was just the start. You need to grossly oversize it if you want the corners to be square. In a few of the photos you can see where the material isn't quite high enough to form the corner...lol but whatever. I was tired of filing! Weld is a lot harder than mild steel so it takes a bit more effort to file.
You can start filing immediately. The time it takes to drop the mig gun and grab a file is plenty of time to "cool".








































































