Teaching a First Timer to Weld

Learn flux-core welding in one real repair.
In this episode of The Fix, we teach a first-timer to weld while repairing a trailer - covering PPE, metal prep, Lincoln 90i FC setup, settings, and beginner bead patterns.
Watch the episode and shop the exact gear we used below.

In this episode of The Fix, Tucker and Travis walk their friend Taylor through a first welding session—setting up a portable Lincoln 90i FC flux‑core wire welder, prepping a trailer, dialing in heat, and practicing beginner‑friendly bead techniques. It’s a practical, real‑world intro that shows how accessible welding can be when you combine the right PPE, prep, and process.

What Welding Is (and Why It’s Useful)

Welding fuses metal to metal by creating a molten puddle that solidifies and ties parts together—strength you can count on for tasks ranging from pipe work to everyday repairs.

The Machine: Lincoln 90i FC 

The team uses a Lincoln 90i FC (flux‑core) wire‑feed welder—“FC” indicating gasless flux‑core operation. The wire on a spool feeds through the gun and acts as the electrode, and you attach a ground clamp to the workpiece to complete the circuit. It’s compact, easy to move, and runs on a standard 120V, three‑prong outlet—handy for farm or field fixes—while flux‑core’s self‑shielding arc makes it unfazed by wind.

Loading the wire: Open the machine, mount the spool on the spindle, guide the wire through the drive and liner to the gun, then close and feed through.

Safety First: PPE That Actually Gets Worn

• Eye & face protection: use a face shield for grinding, and an auto‑darkening welding helmet (auto‑shade) for welding so you can see to position the gun before the arc strikes.
• Hands & body: wear gloves and a fire‑retardant welding jacket—flux‑core throws sparks, and FR fabric prevents pinholes in your clothes.

Tucker’s note: “I’ve had metal shards pulled from my eyes—don’t skip PPE.”

Surface Prep: The Foundation of a Good Weld

They grind out an old, lumpy weld and remove spatter so fresh metal will tie in cleanly. After prepping a bright patch, they attach the ground to ensure a solid electrical path. Clean metal + good contact = better beads.

Settings: Heat (Voltage) and Bead Size

Voltage = heat. Too high can over‑melt and blow through; too low leaves a cold bead that doesn’t fuse. Bead size and settings depend on material thickness, so Travis runs test beads on scrap to dial it in before touching the workpiece.

Beginner Technique: See the Puddle, Then Move It

Travis teaches Taylor to watch the molten puddle and guide it with small motions—circles/crescents, half‑moons, or a gentle zigzag—to wet in both sides of the joint. Hold the gun like a pencil (close to the work), and keep your movement steady so the puddle fills gaps and lays down that classic “stacked dimes” look.

Field‑Ready & First‑Timer Approved

For a small portable unit, the 90i FC proves easy to set up and comfortable for a new welder to learn on. The crew calls it impressive for utility repairs—something you can toss in the car and take to a job when a bracket or rail needs to be stitched back together. Taylor’s verdict on first welds: “It was a blast.”

Quick‑Start Checklist 

1. Suit up: FR jacket, gloves, auto‑darkening helmet, face shield for grinding.
2. Prep metal: grind to clean steel; knock off old spatter; clamp the ground.
3. Load wire: mount spool; feed through drive/liner to the gun.
4. Set voltage/wire speed for your thickness; run test beads.
5. Watch the puddle: use small circles/half‑moons/zigzags; keep a steady travel speed.
6. Inspect & adjust: if it’s sitting high/cold or blowing through, tweak voltage and travel.

Safety disclaimer:

Welding, grinding, and hot work involve risk. Follow local codes and the machine’s owner’s manual, work in a ventilated area, and use appropriate PPE at all times. 

FAQs

Is flux‑core gasless?
Yes—this unit uses flux‑core wire, so there’s no external shielding gas required.

Can I weld outdoors with this setup?
Flux‑core’s self‑shielding arc makes it less sensitive to wind, which is why it’s popular for field repairs.

What power do I need?
A standard 120V three‑prong outlet is sufficient for this machine.

Why are auto‑darkening helmets helpful for beginners?
They darken automatically when the arc strikes, so you can see to aim and keep the gun steady before welding—no need to flip a static lens up/down.