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How to set up and use an arc welder

Arc welder and cords displayed on a timber workshop bench.

Overview

Arc welding, also known as stick welding, is a welding process that uses an electric arc to create a high-temperature welding area that can join metal together. Arc welders are a popular choice amongst D.I.Y. enthusiasts who enjoy building or repairing things at home. They can be used to create custom metal furniture, sculptures, and other decorative items. Additionally, arc welding can be used to repair metal items around the house, such as garden tools, bicycles, and patio furniture.

Whether you’re a beginner or a seasoned expert, it's important to follow proper safety procedures and prepare your workspace accordingly. We'll walk you through the steps to set up your arc welder and provide advice for achieving optimal welding results. 

Safety tip: Always wear the appropriate safety equipment (safety glasses, gloves, ear muffs and a mask, for example) and always follow the instructions for the product or equipment.

Steps

  1. 1

    Take proper safety precautions

    To ensure safety while using an arc welder, it's crucial to be aware of potential hazards. The welding process generates high temperatures, leading to sparks and small, flying pieces of hot metal. Work on non-combustible surfaces like steel, concrete or a welding table to mitigate these hazards. Clean your work surface using a wire brush before starting, and make sure you have all the required safety equipment, such as welding gloves, a welding helmet with a filter lens, protective clothing, and a welding curtain.

    Bunnings team member standing in front of safety equipment.
  2. 2

    Plug in the machine

    Prior to powering up the arc welder, make sure that the machine's power switch is turned off and then plug the input power lead into a wall socket.
    A person plugging in a stick welder electrical cord into a powerpoint.
  3. 3

    Connect the leads

    Attach the arc and earth leads to the correct welding terminals, twist them, and ensure they are securely locked for a strong connection.

    DCEN (Direct Current Electrode Negative) is also known as straight polarity; it is commonly used for welding mild steel and stainless steel. DCEP (Direct Current Electrode Positive) is also known as reverse polarity; it is used for welding cast iron, hard surfacing, and non-ferrous metals.

    For DCEN/straight polarity, connect the earth clamp to the positive terminal and the electrode holder connector to the negative terminal.

    For DCEP/reverse polarity, connect the earth clamp to the negative terminal and the electrode holder connector to the positive terminal.

    Bunnings team member connecting leads to an arc welder.
  4. 4

    Connect the earth clamp

    Next, attach the earth clamp to either the metal being welded or the work surface to establish a proper electrical current flow through the metal. The earth clamp is crucial for maintaining proper electrical flow during welding.
    Bunnings team member connecting earth clamp to arc welder.
  5. 5

    Prepare the electrode

    To insert the electrode into the holder, take the handpiece and press its handle to open the tongs. Carefully slide the electrode into the holder and release the handle to securely clamp the electrode in place.
    Bunnings team member preparing electrode for stick welding.
  6. 6

    Turn the machine on

    Make sure the electrode and handpiece are held clear of the work surface to avoid accidental contact. Activate the stick welding machine by flipping the switch located at the back of the machine. Double-check that the machine is functioning properly before proceeding.
    A person turning an arc welder on.
  7. 7

    Adjust the current

    To customise the welding current for your specific job, rotate the welding parameter adjustment knob until the desired level is displayed. Take caution not to exceed the recommended amperage range for the electrode you're using.
    Close up of arc welder current dial.
  8. 8

    Try MIG welding

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Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.