Hello Gentlemen;

The time has come to formalize and put to pen what has been commonly referred to as the "Farm Code" or in some circles the "Standard of Commercial Welding".

I would like to propose the following:

The committee to draft such a work of useless but necessary information be open to all wishing to incorporate their collective useless misinformation as they may care to share.

The "Standard of Commercial Welding or Farm Code" shall be known as "The Other Red Book".

To start I propose the inclusion of the following suggestions (remember, there are no requirements in the "Standard of Commercial Welding" or "Farm Code"):

Preheat: Regardless of the type of base metal, preheat shall be sufficient to drive all moisture from the pores of the base metal or until it stops "sweating". Once dried, additional preheat is a waste of gas and money.
For critical jobs on any aluminum alloy, smoke the base metal with an acetylene flame and heat it with an oxidizing flame to burn off the carbon black.

Filler Metal for GTAW:
Coat hangers and SMAW electrode with flux removed may be used. 

Precleaning:
Not required if the amperage is increased to "burn out the oxides"
Removal of cutting dross: not required. A good welder and high amperage can burn through it.
Paint or oil: turn up the amperage and burn it in.

SMAW:
Electrode conditioning: Short the end of the electrode (including damp low hydrogen electrodes) to the workpiece until the flux on the rod turns red.
Additional filler metal can be added to really big blow holes, burn through, and other gaping openings by manually adding flux free SMAW electrode to the weld puddle.
Electrodes that have been wet can be "sun dried" prior to use. Disregard any white powdery substances or cracked or flaking flux coating. Increased amperage may be required.
Electrodes of questionable origins or pedigree may be used if inspection is not required or if no cracks are observed when the weld is completed.
Electrode ovens can also serve double duty as an oven for drying wet gloves, work boots, and pizza.
Electrode ovens should only be turned on if the electrode is noticeable damp or wet.

Back gouging:
Not required unless the inspector is looking over your shoulder and insistent that it be performed.
Extent: just enough, but not too much. Minor slag inclusions, porosity, and incomplete fusion can be burned out by the next weld pass.

Post cleaning:
Not required. The slag covers many defects and protects the weld from rain, snow, and paint.

Oxygen bottles shall be filled with clean dry air per good industry practices.
Oxygen bottles shall not be thrown to the ground from heights greater than four stories. The ground should be soft enough such that the bottle does not bounce more than three feet into the air nor should it bounce more than once.
All threads should be liberal slathered with thick grease before attaching the regulator. It is best to stand to one side in case there is an explosion when the oxygen valve is opened. Tighten the gland nut until you hear an audible squeak.

Acetylene valve that have frozen with ice can be effectively thawed using a cigarette lighter. Always leave a 12 inch adjustable wrench in the area just in case the acetylene tank has to be turn off in a hurry. 

Fitup shall be "good enough".

Acceptance Criteria: As long as it holds, its good. If it breaks, add more weld.
Weld size: make it big enough that it won't break.
Weld length: make it long enough that it doesn't break.
Tack welds: that's big enough.
Slag inclusions: turn up the heat and burn it out with the next pass. If additional weld isn't required, paint it.
Porosity: see slag inclusions above.
Cracks: weld over it before the inspector sees it.
Incomplete fusion: see cracks above.
Overlap: no problem, there's fusion under there somewhere.

Magnetic Particle Testing shall be limited to nonferrous metals or when the suspected defect is no less than 1 inch below the surface. Back gouges shall be tested from the first side welded.

Penetrant Testing shall incorporate the use of solvent (gasoline, kerosene, alcohol, acetone, etc.) to flush off any penetrant from the surface to be inspected. Excess penetrant may be removed using a paint brush saturated with one of the solvents listed. Developer need not be used if the defects are large or there is no burning desire to find said defects. If used, a heavy dripping coating is better than several light layers. Surfaces may be prepared by grit blasting or power brushing.

Ultrasonic Testing: calibration blocks are not required. Calibration may be accomplished using the edge of a beam or plate if angle beams are used to search for cracks or other things. Straight beam scanning is only required if a lamination is know to exist.

Please feel free to add any useless misinformation you feel is fitting for such a work of merit. I have others, but I can't wait to see yours!

Best regards - Al