TIG Welding a Huge Gap? Here’s How to Make It Disappear
TIG welding a big gap can feel like an impossible challenge. You’re trying to lay down a clean, strong weld, but instead, you’re staring at a huge, uneven space between your pieces. So, do you scrap the project and start over? Nope! With the right approach, you can bridge that gap and make it look as if it was never there.
Why Gaps Are a Problem
A properly fitted joint makes welding easy, but when you’re dealing with a gap, things start moving, shifting, and distorting. That’s where a solid setup comes in. Locking everything in place before welding—using a jig, clamps, or even scrap metal—will save you a ton of frustration.
The Trick: Buttering the Joint
Instead of jamming filler into a massive gap, take it step by step:
- Build up the edges first. This technique, called buttering, creates a solid foundation before fully bridging the gap.
- Control your heat and filler. Use steady, controlled movements to lay down material without burning through or making a mess.
- Keep things flat. You want the final weld to sit flush, not concave. Some post-weld work with a grinder and a Scotch-Brite pad will help smooth out the welded areas.
Final Touch: Making It Look Flawless
Once the gap is filled, it’s time to make the weld disappear. Start with an 80-grit sanding finish, blend with an orbital sander, and refine everything with a hand Scotch-Brite pad. If done right, the joint will look like it was always a perfect fit.
Want to see exactly how this works? Watch the full video here
This technique isn’t just about fixing a bad fit up—it’s about learning how to control your welds, prevent distortion, and work smarter on any project. Give it a shot
