Turn up the heat, it should burn it off... the rocker is thick steal, it will take everything that welder can throw at it if you are carefull. if that doesnt work, take a screw driver and score a line down the galvanising where you are going to weld to help the welder get some clean steal to weld to.

Did the wire brush take the galvanising off? i wouldn't think it would...

good luck
- Jason

 

I agree. You need to get the zinc out of the way and weld to the steel underneath. A file or grinder should do the trick.

Phil

 

Be careful welding galvanized - the fumes are NOT good for you - Your best bet is to grind the zinc off before welding. It's thin and soft - it comes right off..

 

The galvanizing should not be problem,the heat of the weld puddle should burn right through it.Be careful not to breathe the fumes from the weld,not good for you.
Also be aware, the wire wheel is contaminating the weld area. When using the wire wheel it leaves some of itself behind, this can be part of your problem. Sand the area to be welded don't wire wheel it.

 

For the other side I would take a grinding wheel to the rocker and just skim the galvanization off the steel before attempting any welds there:

A for what’s already been done, your best bet is to carefully grind down those welds that didn't stick, grind off the galv. the best you can (a dremel or die grinder with a long burred bit might help with this) and try again. You may end up having to make a few passes in these areas to get good penetration.

You should also make sure the Mig's power is set as high as it will go and run the wire feed slower than usual. This will allow time for the metal to get hotter and have a better chance of burning off the galvanization.

Ken

 

Thanks for all the tips. I will work on grinding off the zinc for a cleaner weld and give that a shot.