Attaching cast fence caps to steel fence posts

[eddie]

I have a cast iron, 2" ball, fence post cap to top off a 2-1/2 sq tube steel fence post...about twenty of them.


With all the talk of problems with trying to weld cast iron, any tips for trying to tac them on ...just a few tacs ought to do it. (HH140).

Or just use some sort of epoxy,..if it will be strong enough to keep someone from twisting them off...recommendations on an epoxy?

thx

[Jim-Tx]

I've had no problems tacking cast post tops with my MM210 and 70s-6 wire. They will hold plenty good for ornamental use with about a 3/8" tack weld. I like the caps that fit over the top of the post. Is that what you have? The caps in the picture fit over 1.5" square and are tacked at the corners. Sorry about the TINY picture. I don't suppose Hobart and Miller can afford a bigger storage drive.

[Hotfoot]

I've begun welding a number of cast to cast and cast to steel small jobs with my flux Core 125EZ. It seems all the vintage lawn furniture needs some repair or another, and I've done beds, tables, chairs, etc...all with the 125. You will probably be surprised how nice it welds! Works fine for ornamental work...but will not pass the "Drop it on the concrete floor" test.

[MAC702]

There is nothing structural here. It just has to not blow off in the wind, and maybe survive kids shaking the fence, and stuff like that. I use whatever process I built the rest of the fence with. For wire processes, FCAW works better, but if I'm in the shop using GMAW, then that's what it gets.

[welderburn2000]

dril a hole in area likely not to be seen an plug weld it to the post

[MAC702]

That would get old!

[Hotfoot]

Just MIG it Mac...You'll see!!

[Monte55]

I have welded hundreds of them on 2" square posts I use for deck railing etc.
I tack two opposite corners and make sure it sits straight on the post. I weld
all four sides with vertical down using mig and all is fine. I kind of like the ping sounds they make after welding and cooling down. Not all the cast caps will sit on the post perfect. It also helps to cut the post square.

[eddie]

I have welded hundreds of them on 2" square posts I use for deck railing etc.
I tack two opposite corners and make sure it sits straight on the post. I weld
all four sides with vertical down using mig and all is fine. I kind of like the ping sounds they make after welding and cooling down. Not all the cast caps will sit on the post perfect. It also helps to cut the post square.

Mine went over the post so I just got underneath and did about a half inch tac on two sides and it worked!

Yeah, the snap, crackle, pop made me think it was gonna' blow off...but not so...and you're so right about having the post top square....