Forget the larger 1 8 inch tungsten electrode and use a smaller one.
Welding sheet metal copper.
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Take the time for proper fit up proper tight part fit up is especially important when welding thin materials.
Tig welding sheet metal.
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For cv mig welding on sheet metal wire diameters of 035 inch are recommended.
And it also traps argon in the weld puddle area.
The back side of the weld on sheet metal gets hot and molten and needs shielding gas too.
As a rule when mig welding sheet metal never use a body filler metal that is thicker than the base metal.
In welding copper sheets the heat is conducted away from the welding zone so rapidly that it is difficult to bring the temperature up to the fusion point.
Anyway back to the part about the copper.
It is often necessary to raise the temperature level of the sheet in an area of 6 0 to 12 0 in.
It is recommended that a welder should use 023 or 024 inch wire for light gauge sheet metal work.
Don t attempt to weld thin materials like sheet metal with flux cored wires which put more heat into the base metal.
Mig welding is the preferred method for most automotive bodywork and since sheet metal is the thinnest of metals a large expensive mig unit is usually not required.
While wire feed welding sheet metal go for short bursts of welding instead of a going on a long bead.
152 4 to 304 8 mm away from the weld.
A 100 argon shielding gas is the most common in mig welding aluminum sheet metal.
P deoxidized copper contains low amounts of oxygen but tends to have up to 0 05 phosphorus and 0 05 arsenic which can release fumes.
This alloy generally has less than 0 02 oxygen.
The majority of the sheet metal welding i ve done was with a 90 amp 110 volt welder.
Short bursts or tacks will help.
For sheet metal i use ine welding wire and it is just as good as their flux cored wire if you want you can grab one here.
To weld sheet metal with solid wires use electrode positive ep or reverse polarity.
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It draws heat out of the metal you are welding if it is in close contact like with a chill block 2.
Sheet metal copper backing does 2 things.