OK. well I purchased a Lincoln Pro-Core 100 today and a Performance Welding book. I plan on practicing first on the old outer pulley. A demo video came with the welder also. There is a chart included, for settings, and the wire spool included with the welder is wire NR-211-MP, .035"., E71T-11.

So....additional edit now: . I will need to add approx. .3 mm on metal into the groove on the hub at the deepest point.

I did my first practice welding tonight. So practicing on the old pulley, I was able to build up at the above depth on a small experimental area.

The practicing weld looked rough, black and bumpy. However, it feels quite strong.

My main idea here will be to be able to file down the additional fill so the added fill will be smooth to receive the new pulley.

I would prefer to work on and off on the final weld for a few days. Would the strength of the new weld, on the hub be affected, were the welding be done off and on for a number of days?

You should be able to leave sit with no adverse effects. It sound like you are useing a cored wire which always looks bumpy and overall kind of crappy. They are still strong but just not as pleasing to look at. As far as filling just fill up beyond where you need to and then file down . you should be good to go.

Ben

OK. Today I do some filing practice of the weld build on the old pulley.