i have a stick welder (arc) and its minimal setting is 40amps is it possible to modify it so i can get lower amps? its just a cheap welder with a knob on the front to adjust the settings from 40amps to 140amps. i only ask this cause i want to weld 1.0mm steel with it and i refuse to spend on a mig or tig machine cause i will never use it the arc is perfect for me cause i weld a lot of thick stuff with it as well and rods are nice and cheap.
Bad news, my friend. I would strongly advise against welding anything thinner than 2 mm with a stick welder. I live in the USA so I deal with fractional imperial units (we're a bit nutty over here...... lol) The thinnest welding rods you can get here are 1/16 inch, I guess that's about 1.5mm.
Even using DC electrode negative a.k.a. DC reverse, you'd have a hard time avoiding burn-through on 2mm material using 1.5 mm rods. And those 1.5mm rods disappear really fast..
There's no way you'll be able to make a consistent weld on 1mm using stick welding. You'll be forced to travel so fast that you only get marginal penetration and fusion through most of the weld. Read: welds that snap off like dry twigs.
1mm is solidly in MIG welding territory, I'm afraid.
A better option would be self drilling sheet metal screws. like these:
HVAC installers and guys who do sheet metal roofing and siding use these for everything.
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