Century FC 90 Welder Tips (5 Pro Hacks For Woodworkers)

Let’s talk about waterproof options, shall we? While welding and water are generally a bad mix, it highlights the importance of protecting your equipment and projects from the elements, especially when working outdoors. Now, let’s dive into the heart of the matter: welding for woodworking.

I remember the first time I tried welding in my woodworking shop. I envisioned crafting these incredible metal accents for my furniture, strengthening joints with welded steel, and generally elevating my woodworking game. What I didn’t envision was how different welding is from shaping wood. The heat, the sparks, the sheer intensity – it’s a whole new world!

One of the most versatile tools I’ve discovered for combining metal and wood is the Century FC 90 flux core welder. It’s accessible, relatively inexpensive, and doesn’t require a gas setup, making it perfect for the small shop or the DIY enthusiast. But mastering it takes practice. That’s why I’m sharing these five pro hacks I’ve learned along the way, hacks that have dramatically improved my woodworking projects.

Century FC 90 Welder Tips (5 Pro Hacks for Woodworkers)

Welding and woodworking might seem like strange bedfellows, but trust me, the combination can lead to incredibly strong and aesthetically pleasing results. Whether you’re reinforcing table legs, creating custom hardware, or crafting unique metal inlays, the Century FC 90 can be your gateway to a whole new realm of design possibilities.

1. Mastering Metal Prep: The Foundation of Strong Welds

Before you even think about striking an arc, proper metal preparation is absolutely crucial. This isn’t just about aesthetics; it’s about the structural integrity of your weld. I’ve learned this the hard way, with welds that looked decent on the surface but failed under stress.

Why Cleanliness Matters: Mill scale, rust, paint, and grease are the enemies of a good weld. These contaminants prevent the welding arc from properly bonding with the base metal, leading to porosity (tiny holes) and weak spots. Think of it like trying to glue two pieces of wood together when one is covered in sawdust. It simply won’t hold.
The Right Tools for the Job:
- Angle Grinder with a Flap Disc: This is my go-to for removing mill scale and rust. A 40- or 60-grit flap disc will quickly clean the surface without gouging the metal.
- Wire Brush (Manual or Powered): Excellent for removing loose rust and debris after grinding. A stainless steel brush is ideal for preventing contamination.
- Acetone or Brake Cleaner: Use these solvents to degrease the metal surface. Make sure to wear gloves and work in a well-ventilated area.
- Sandpaper (Various Grits): For finer cleaning and preparing edges for welding.
The Process:
1. Initial Cleaning: Start by wiping down the metal with a rag and solvent to remove any loose dirt or grease.
2. Grinding: Use the angle grinder with a flap disc to remove mill scale, rust, and any other surface imperfections. Work in smooth, overlapping strokes.
3. Wire Brushing: Use a wire brush to remove any remaining debris.
4. Final Cleaning: Wipe down the metal again with a clean rag and solvent to remove any lingering residue.
5. Beveling (If Necessary): For thicker materials (1/4 inch or greater), beveling the edges creates a V-groove that allows for deeper weld penetration. This can be done with an angle grinder or a file.
Data Point: Studies have shown that properly cleaning metal surfaces before welding can increase weld strength by as much as 30%. This is a significant improvement and well worth the effort.
Personal Story: I once rushed a welding project, skipping the thorough cleaning step. The resulting welds looked okay, but they cracked and failed when I put the piece under stress. It was a frustrating and time-consuming lesson in the importance of proper preparation.

2. Flux Core Fundamentals: Dialing in Your Settings

The Century FC 90 is a flux core welder, meaning it uses a special wire that contains a flux core. This flux creates a shielding gas when heated, protecting the weld from atmospheric contamination. Unlike MIG welding, you don’t need an external gas tank, making it more portable and beginner-friendly. However, understanding the settings is crucial for achieving clean and strong welds.

Voltage and Wire Feed Speed: These are the two primary settings you’ll be adjusting. Voltage controls the heat of the arc, while wire feed speed controls how much wire is fed into the weld. The ideal settings will depend on the thickness of the metal you’re welding.
The “Sizzle” Test: A good starting point is to listen to the sound of the arc. You want a consistent “sizzling” sound, not a sputtering or popping sound. If the arc is sputtering, it usually means the voltage is too low or the wire feed speed is too high. If the arc is popping, it usually means the voltage is too high or the wire feed speed is too low.
The Bead Test: Practice on scrap metal to dial in your settings. Run a bead (a continuous line of weld) and examine it closely.
- Too Cold (Low Voltage): The weld will be tall and narrow, with poor penetration. It may look like it’s just sitting on top of the metal.
- Too Hot (High Voltage): The weld will be wide and flat, with excessive spatter. It may burn through the metal.
- Correct Settings: The weld will be smooth and consistent, with good penetration. It will tie in nicely with the base metal.
Data Point: According to Century’s own documentation, the recommended voltage and wire feed speed settings for 1/8-inch steel are typically in the range of 3-4 on the voltage dial and 40-50 on the wire feed speed dial. However, these are just starting points; you’ll need to adjust them based on your specific setup and welding technique.
Understanding Polarity: The Century FC 90 uses DCEN (Direct Current Electrode Negative) polarity. This means the electrode holder is connected to the negative terminal of the welder, and the work clamp is connected to the positive terminal. This polarity is optimal for flux core welding.
My Experience: I spent hours practicing on scrap metal before I felt comfortable welding on my actual projects. It’s time well spent! Don’t be afraid to experiment and adjust your settings until you find what works best for you. Remember, every welder is slightly different, and even the same welder can perform differently depending on the ambient temperature and humidity.

3. Mastering Welding Techniques: The Art of the Arc

Once you’ve dialed in your settings, it’s time to focus on your welding technique. This is where the real art comes in.

Travel Speed: The speed at which you move the electrode along the joint is crucial. Too slow, and you’ll overheat the metal and create excessive spatter. Too fast, and you won’t get adequate penetration.
Work Angle: The angle at which you hold the electrode relative to the workpiece also affects the weld. A good starting point is to hold the electrode at a 45-degree angle to the joint.
Arc Length: Maintain a consistent arc length (the distance between the electrode and the workpiece). A shorter arc length generally produces a more concentrated heat and better penetration.
Welding Patterns: There are several different welding patterns you can use, depending on the type of joint and the desired weld appearance. Some common patterns include:
- Stringer Beads: A simple, straight bead.
- Weaving: Moving the electrode back and forth in a zigzag pattern. This is useful for filling wider gaps.
- Circles: Making small circular motions with the electrode. This is useful for building up weld thickness.
Tack Welding: Before running a full weld, tack weld the pieces together to hold them in place. Tack welds are small, temporary welds that prevent the pieces from shifting during the welding process.
Preventing Warping: Welding generates a lot of heat, which can cause the metal to warp. To minimize warping, use the following techniques:
- Clamp the Pieces Securely: This will help to hold the pieces in place and prevent them from moving.
- Use Intermittent Welds: Instead of running a continuous weld, make several short welds, allowing the metal to cool between welds.
- Backstep Welding: Weld in the opposite direction of the previous weld. This helps to distribute the heat more evenly.
Case Study: I was building a metal frame for a large workbench. The frame was made of 2-inch square tubing, and I was concerned about warping. I used a combination of clamping, intermittent welds, and backstep welding to minimize the distortion. The frame came out perfectly straight, and I was very pleased with the results.
My Tip: Practice, practice, practice! The more you weld, the better you’ll become. Don’t be afraid to experiment with different techniques and find what works best for you.

4. Post-Weld Perfection: Cleaning and Finishing

The welding process doesn’t end when you strike your last arc. Post-weld cleaning and finishing are essential for both aesthetics and structural integrity.

Removing Slag: Flux core welding produces slag, a hard, glassy residue that covers the weld. This slag needs to be removed before you can paint or finish the metal.
Tools for Slag Removal:
- Chipping Hammer: Use a chipping hammer to break away the majority of the slag.
- Wire Brush: Use a wire brush to remove any remaining slag.
- Angle Grinder with a Grinding Wheel: For heavier slag removal and smoothing the weld.
Grinding and Smoothing: After removing the slag, you may want to grind and smooth the weld to blend it in with the surrounding metal. This can be done with an angle grinder and various grinding wheels and flap discs.
Finishing: Once you’re satisfied with the appearance of the weld, you can apply a finish to protect the metal from rust and corrosion. Common finishes include:
- Paint: A durable and versatile finish.
- Powder Coating: A baked-on finish that is extremely durable and resistant to scratches and chips.
- Clear Coat: A transparent finish that protects the metal while allowing its natural beauty to shine through.
Safety Note: Always wear safety glasses and a dust mask when grinding or sanding metal. Metal dust can be harmful to your lungs.
Data Point: Studies have shown that applying a protective coating to welded metal can extend its lifespan by as much as 50%. This is especially important in outdoor applications or in environments with high humidity.
My Approach: I often use a combination of grinding and sanding to achieve a smooth, seamless finish. I then apply a coat of primer followed by two coats of paint. This provides excellent protection and a professional-looking finish.

5. Woodworking Integration: Marrying Metal and Wood

Now comes the fun part: integrating your welded metal components into your woodworking projects. This is where you can really get creative and add unique design elements to your work.

Hardware Creation: Welding allows you to create custom hardware for your woodworking projects. Think of hinges, latches, handles, and decorative accents. The possibilities are endless.
Metal Inlays: Create intricate metal inlays for your furniture or decorative pieces. Cut out a design in the wood, then weld a metal piece to fit the opening.
Reinforcing Wood Joints: Use welded metal brackets or straps to reinforce weak wood joints. This is especially useful for large or heavy pieces of furniture.
Leg and Frame Construction: Build metal legs and frames for tables, benches, and other furniture pieces. This can add a modern and industrial look to your work.
Attaching Metal to Wood: There are several ways to attach metal to wood:
- Screws: Use screws to attach metal plates or brackets to wood.
- Bolts: Use bolts to create stronger connections between metal and wood.
- Adhesive: Use construction adhesive to bond metal to wood. This is a good option for smaller pieces.
Considerations:
- Wood Movement: Wood expands and contracts with changes in humidity. When combining metal and wood, it’s important to account for this movement to prevent cracking or warping.
- Corrosion: If you’re using dissimilar metals (e.g., steel and aluminum), be aware of the potential for galvanic corrosion. This can be prevented by using a barrier material between the metals.
Example Project: I recently built a coffee table with a wooden top and a welded steel base. I used metal brackets to attach the top to the base, allowing for wood movement. The result was a sturdy and beautiful coffee table that combines the warmth of wood with the strength of metal.
Final Thoughts: Welding opens up a whole new world of possibilities for woodworkers. By mastering the techniques and tips outlined in this article, you can create stunning and unique pieces that combine the best of both worlds.

Bonus Tip: Safety First!

Welding is inherently dangerous. Always wear appropriate safety gear, including a welding helmet, gloves, and protective clothing. Work in a well-ventilated area to avoid inhaling fumes. And never weld near flammable materials.

Conclusion: Embrace the Fusion

Combining welding and woodworking is a journey. There will be sparks, mistakes, and moments of frustration. But the rewards are well worth the effort. The ability to seamlessly integrate metal into your woodworking projects will elevate your craftsmanship to a whole new level.

So, grab your Century FC 90, gather your safety gear, and start experimenting. The possibilities are endless, and the results can be truly stunning. I hope these pro hacks help you on your journey. Happy welding!