Butt Welding 1" x !/2"

Hi,

We are welding track at my ride-on railway club and often have to butt weld the a running rail due to a section being replaced for corrosion, damage or just old-age.



The rail to sleeper weld is easy and always goes well.



The weld of the old running rail to the new is difficult and needs a lot of grinding to get alignment in the vertical and horizontal of the wheel running surface, and to avoid a dip that is noticeable when wheels pass over the joint.



We have available standard 3.2, 2.5 and 1.6 rods.



Currently:

Prep sides only about 2 x 2 mm.

Two alignment bars clamped, one top and one on the inside of the running surface.

Heavy 3.2 tack at the bottom outside.

Heavy tack above the first.

Remove inside clamp bar.

Heavy tack at bottom inside.

Heavy tack above the first inside.

Remove top clamp bar.

Change to 2.5 mm rod.

Tack inside and out at top of bar.

Run bead across the top.

Grind to shape.



Could someone give us a hint on preparation, rod selection and sequence of welding that will give us a good result without a dip.



Thanks for any guidance,

John