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How to Create Accurate Weld Effects

Basic Welding Simulation

Now that we know how to make our weld seams let us put the practice into theory. In this section we shall make some simple welds.

Example 1: 90 fillet weld (convex)

This is the simplest type of weld to make. In Pic 1 we can see the rolling out of milliput to very fine diameters the secret is at all times to keep your fingers, milliput and work surfaces wet! In this image the weld is currently about half the final diameter that we require to do our work.
Pic 2 shows the templates that we will use for our weld examples, basically they are squares of styrene covered with a grey primer in order to make a good photographic colour contrast.

To lay the weld we wet with a paintbrush the corner groove that we are to use and then lay the milliput roll into that same space.

Now that we have the weld roll in place we must cover the area in water. This will serve to blend the edges of the milliput to the sectional surfaces as well as providing a medium that will prevent the weld tool from sticking to the milliput. Let the milliput harden for a few minutes so that a surface skin forms before applying another small amount of water

In Pic 4 we can see the weld tool in a pin-vice before application to the milliput surface. To create a convex weld we use the OPEN end of the groove in the tool, facing the weld, and then sharply jab the tool repeatedly, but not deeply, into the surface of the milliput. What we are trying to achieve is a ridged effect that is semi-circular in shape but that does not penetrate completely the milliput. Always draw the tool down the weld, i.e. as in the direction of the arrow as shown to the left as this will create the correct overlapping nature of the weld. It is VERY important to keep the end of the tool wet when welding otherwise the milliput WILL lift from the surface.

Detailing Tip:

When creating such welds I always
use a monocular eyepiece (x10) as
I find that this allows me to examine
the work very closely and allows
fine welds to be created.

In Pic 5 we can see the finished weld before a final blending of the edges with water and a paintbrush into the sectional surfaces again (application of the weld tool will always tend to move the milliput around regardless of how careful you are). In this image you can see how certain areas are tidy, others are rough and downright messy, but overall we have an accurate 3-dimensional fillet weld. The look of the finished weld is purely up to how you want you work to look again depending on the time frame and type of vehicle/weld being simulated.
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