Welding galvanized steel: do not, and if you must, here is how
Difficultymedium
Zinc fumes cause metal fume fever: chills, aches, a night you will not forget. Grind the coating off 1" either side of the joint (it looks dull grey when the zinc is gone), weld outside or with a fume extractor pulling from behind the joint, wear a P100 respirator under your helmet, and re-coat with cold galvanizing spray after. Milk does not help; that is a myth.
Fence posts, chain link rails and unistrut are all galvanized. Plan for it.
#galvanized#safety#fumes#welding
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Question: do you need to disconnect power for this or is it safe to leave it plugged in?
Tried this over the weekend and it worked first time. Thanks for writing it up properly.
I did the same repair last month and your step 3 is where I got stuck. Wish I had this then.