Can You Stick Weld A Car Frame (Easiest Way To Do That)

Stick welding is a pretty popular name in the maintenance and repair industries. Affordability, ease of use, and versatility make it ideal for every welder.

But when it comes to welding a vehicle frame, a question may pop up in your mind – can you stick weld a car frame?

Read further to get details about it. 

Is It Safe to Weld on a Car?

Welding on a car has both safe and risky sides. To stay in the safe zone, you must learn how to protect your car’s electronics during a weld. Besides, getting familiar with the vehicle manufacturer’s instructions is equally necessary.

Last but not least, try out the safest method possible, including the correct gas, equipment, and other flammable stuff.

Can You Stick Weld A Car Frame?

Stick welding a car frame is a bit tricky, yet possible. Many automotive experts often take assistance from stick welding as it doesn’t require any extra shielding gas.

That said, it tends to produce too much debris from time to time, which is why beginners won’t find it a more accessible welding technique to try out.

What are the Tools & Things You Need before Car Frame Welding?

Of course, you must gather specific tools and equipment to perform car frame welding. These are as follows:

Stick Welder

Stick Welder

Stick welding is considered one of the three common types of welding procedures for being cost-efficient and versatile.

It doesn’t require you to spend extras on an additional shielding gas; plus, it’s easy to perform while welding nickel, copper, aluminum, and steel.

When it comes down to welding a car frame, you must spend on a top-class stick welder that can smoothly perform its welding task.

And make sure to choose the one you can comfortably use in windy conditions.



One of the most confusing parts is choosing the ideal electrode for car frame welding. Because around the current marketplace, tons of different models are available, each serving other characteristics.

As car frames tend to be manufactured with sheet metals, you better rely on the E6013 for the best outcomes. As an alternative, you can also choose any of the ones between 6011, 6010, 6013, or 7024.

Safety Equipment’s

Safety Equipment

Proper safety gear is the key to staying in the safe zone during stick welding. Unfortunately, this particular welding method tends to produce excessive amounts of dust and fume.

As a result, you can’t avoid wearing a face mask, gloves, goggles, helmet, and safety boots.

How Do You Stick Weld A Car Frame?

Now that you’re familiar with the necessary tools needed, let’s jump right into the steps of how to stick weld a car frame:

Step-1: Get the Surface Clean

First, eliminate the dust or debris from the surface of your car frame using paper towels

A typical piece of rag may leave scratches during a clean-up, so you should highly avoid it. Alternatively, use a bit of wire brush to get that area dust-free.

Step-2: Go for the Current Setting

Before you start stick welding, I’d recommend setting the amp based on your electrode. As a rule of thumb, one amperage is sufficient for every .001″ electrode diameter.

Try to measure it following this approximate count to best use the current setting.

Step-3: Begin Stick Welding

Have you adjusted the current setting and cleaned up the surface thoroughly? If so, your next duty is to turn on the stick welder keeping the heat mediocre.

Remember that excess heating may ruin your project, as sheet metals can’t withstand heavy heating.

Use both of your hands to hold the stick welder properly. Pay focus to the area where you’re striking the arc. Once you notice you’ve formed the arc, lift the welder and join other damages available.

If you’re done, allow the car frame’s join cool. Observe them thoroughly to see whether there are any small gaps or holes. If not, pat yourself on the back as you thoroughly complete the task.

Car Body Welding Common Mistakes and How to Avoid Them?

Some of us make common mistakes during frame welding. And eventually, they end up with the results they weren’t expecting. Let me show you some of them and the way to get rid of them:

Mistake-1: Picking Indoor Places for Welding

It will help if youshouldn’tt try stick welding around the interior surfaces as it produces lots of dust and fume.

How to Avoid It:

  • Make sure to choose an outdoor surface and windy condition to get out of harm and toxicity.

Mistake-2: Applying Too Much Heat

Car frames generally contain thinner sheet metals, which can’t withstand heavy heating. As a result, if you apply excessive heat, those frames may get cracked or seriously damaged!

How to Avoid It:

  • Keep the heat at a mediocre level for safe stick welding. And don’t rush at all.

Mistake-3: Not Cleaning the Surface before Welding

Chances are the frame of your car will get some stubborn spots, especially when you start welding without cleaning up the surface.

Thus, contaminants like oil, dust, or rust get firmly attached to the surface where you strike the arc.

How to Avoid It:

  • Use a wire brush to remove dirt, dust, and such objects. And to eliminate oil or grease, utilize paper towels.

How Much Does It Cost to Stick Weld Car Frame?

The best part of using a stick weld for welding a car frame is that it won’t cost you a pretty penny. A stick welder under $200 is sufficient to get the work done.

Besides that, you have to spend a little more amounts to get the electrodes made for stick welding.

Replacing some joints will be a must if they get completely ruined. In such a case, the cost will be higher than before.  

Is It Illegal to Weld A Vehicle or Car Frame?

No, it isn’t. Federal law doesn’t provide illegitimacy for welding a vehicle frame or a car chassis. However, it is mandatory to take suggestions from your own car’s manufacturer to make sure whether it is legal to weld the frame or not.

It’s also necessary to consult an expert legal advisor, especially when you researching for genuine legal advice.

Last Words!

So, can you stick weld a car frame? The answer is a big “yes.” But for this, ensure you follow all the steps and tricks I’ve mentioned above

A top-quality stick welder, top notch electrodes, and adequate safety dresses are crucial to ensure successful stick welding

Frequently Asked Questions (F.A.Q): 

How thick is a car frame?  

Almost every car instrument uses sheet metal as a primary material; the average thickness is around .085 inches. 

Should you disconnect the battery when welding on a car?

Of course. To stay in the safe zone during a weld, you must disconnect the battery and avoid welding the closer electrical parts of your vehicle.


  • James Smith

    This is James Smith, a Hobbyist welder, welding since my 15th birthday. My father was a professional welding mechanic at a garage and used to take me to garage. My love for welding started then and I learnt basics from my father. At my 15th, my father gifted me a stick welder and my journey to become a welder began. Gradually I accustomed to welding and mastered at tig welding.

Leave a Comment