Remember those old days when welders used hand shields to protect eyes? Well, today’s welding gear has come a long way. One of the COOLEST innovations is the pancake welding helmet, dreamed up by George Gilchrist from Gillette, Wyoming, right after World War II.
Now, when you first hear ‘pancake hoods,’ you might wonder what’s up with that name. But trust me, these helmets are not just unique—they’re super effective too, especially loved by pipeline welders for their specific jobs.
In this article, I’ll walk you through everything about pancake hoods: what they’re made of, how they’re used, and what’s GREAT (and not so great) about them. Ready to explore this welding gear? Let’s go!
What Exactly Is A Pancake Welding Hood, And What’s Its Real Purpose?
A pancake hood is a type of welding helmet that stands out from the traditional gear—they’re round, compact, and flat, just like PANCAKES, which explains their name. One side extends out like a shield, protecting the opposite side of your face from sparks, typically opposite to your welding hand.
What caught my attention about pancake welding hoods was their UNIQUE design. But once I started using one, I was pleasantly surprised—they’re much lighter than the traditional helmets I’ve used before. I quickly discovered they offer way more comfort and convenience, especially for welding pipelines and tackling outdoor projects.
These helmets are designed to shield your eyes and face from welding arcs. They not only block the intense UV rays that can blind you but also keep your hair and face safe from flying debris that welding can sometimes kick up accidentally.
Why Are Pancake Helmets Shaped Like That?
Pancake welding hoods stand out for their distinctive round and flat design. But why this unconventional shape? It’s not just about looks—it’s all about functionality.
The ROUND SHAPE provides comprehensive protection for your entire face, while the FLAT design reduces the distance between your face and the welding area. This closeness enhances visibility and allows for precise welding, which is crucial for intricate tasks.
This unique design makes pancake welding masks particularly effective for projects like pipeline welding. They ensure ample airflow, which is essential for comfort during long hours in hot environments.
When I first tried one, I immediately appreciated how well the viewport fit and how effectively it blocked ambient light, reducing glare. This makes pancake helmets my go-to choice for outdoor daytime welding, where CLEAR VISIBILITY is essential.
Does OSHA Allow Their Use?
Before purchasing a pancake welding hood, make sure it meets the guidelines of The Occupational Safety and Health Administration (OSHA). Such helmets meet all safety requirements, ensuring top-notch quality and protection from hazards.
Here’s the thing: not every pancake hood on the market is OSHA-accepted. Look for labels like ‘ANSI certified’ or ‘ANSI Z87.1 approved’ to verify that the model meets alternative safety standards. It’s wise to ensure all your equipment, not just your welding helmet, meets at least one of these standards.
While OSHA approval is crucial, if your helmet also meets ANSI standards, that’s a big plus.
Pros And Cons Of Using Pancake Hoods
Advantages
Robust yet lightweight build, but not bulky like traditional hoods.
Comfortable to wear for long hours without causing muscle sprain.
Excellent overall protection to eyes, face, neck, and hair during welding.
The flat and round shape allows the closest view of the work object.
It can be easily custom-fitted at home using sandpaper.
Protects eyes from UV rays while working outdoors in strong sunlight.
The balsa box prevents fogging, adding to the clarity of view. This is not possible with traditional hoods without some tricks.
Available in various price ranges to suit different budgets.
Disadvantages
It cannot be worn with conventional safety glasses.
Not all models are compatible with auto-darkening lenses.
It is not practical for welding tasks other than pipelines or working outdoors.
Parts Of A Pancake Helmet And Their Functions
In this section, let us familiarize ourselves with the different parts of a pancake welding helmet and find out about its functionalities.
1. Facepiece Or Hood
The round and flat shell of the hood serves as the facepiece, resembling a pancake. It’s crafted from tough materials like carbon fiber or fiberglass, designed to shield your face, eyes, and neck from the heat, light, and sparks produced during welding.
These materials aren’t just strong—they’re LIGHTWEIGHT too, making it comfortable for welders to wear them for extended periods without straining their shoulders and neck. That’s why pancake helmets are much lighter and less bulky compared to traditional welding hoods.
2. Side Piece
On one side of the facepiece, there is a side shield that protects your face, neck, beard, and hair while welding. The shield’s position depends on your dominant hand: for right-handed welders, it’s on the left; for left-handed welders, it’s on the right.
The round, flat front part, along with the side shield, provides structural support to the other components of the helmet, which we will discuss next.
3. Flip-up Assembly
A flip-up assembly lets you quickly and easily raise the front of your pancake helmet, temporarily exposing your face. This allows you to inspect your workpiece or communicate without removing the entire mask. It should be securely attached to the front of the hood so you can pivot it upwards whenever needed.
The flip-up assembly allows COMFORT and EFFICIENCY when you have to switch between welding and other tasks frequently.
4. Balsa Box
Pancake helmets feature a uniquely designed viewport that houses the lens, which is easy to replace. This contoured box, located at the back of the hood, holds the viewing lens. Made from lightweight and durable balsa wood, the box can be custom-fitted by sanding and shaping it to match the welder’s facial structure and head.
Balsa wood makes the helmet extremely portable and ensures a perfect fit for maximum protection and comfort.
5. Headgear
Your pancake welding hood includes an adjustable headband or strap that keeps the shield securely in place. Simply WEAR the head strap, POSITION it to fit your head comfortably yet firmly, and CORRECT the tightness as needed.
Once you fit the headgear to your preference, you can put on the helmet and adjust the height of the lens. Want to know what’s more interesting? Well, the ratcheting mechanism lets you fix the helmet’s height after wearing it. Personally, I found it very helpful.
6. Respirator (Optional)
Some pancake welding hoods come with an integrated respirator that filters out airborne particles and toxic fumes produced during welding, enhancing your COMFORT and SAFETY. Built-in respirators also ensure adequate airflow to prevent fogging on the lens, maintaining a clear view of the welding area.
7. Viewing Lens
The lens plays a crucial role in your pancake welding helmet by shielding your eyes from intense light radiation and sparks during welding. It not only offers a clear view of the welding area but also protects against harmful UV radiation, which is especially important during extended prolonged outdoor work.
When selecting a pancake welding helmet, it’s essential to consider the type of viewing lens it offers. Most hoods come with passive fixed-shade lenses rather than auto-darkening ones. You can choose the correct shade required for your welding job here: check it out!
But, Why Are They Not Equipped With Auto-Darkening Lenses?
Pipeline welders commonly opt for pancake hoods due to their suitability for straightforward and repetitive welding tasks. In these situations, the rapid adjustment of shades provided by auto-darkening lenses is LESS CRITICAL compared to more complex welding tasks. This explains why such masks often do not feature such lenses.
Additionally, factors such as personal preference and the weight of the helmet play important roles in this choice. Many welders appreciate the simplicity of standard, fixed-shade lenses that do not rely on batteries or electronics. Moreover, auto-darkening lenses tend to add extra weight to the pancake hood, which is not desirable for this particular application.
So, How To Fit A Pancake Welding Hood?
Before you dive into using your pancake helmet, it’s crucial to nail down the perfect fit. The upper curve of the balsa wood box, where your forehead rests, needs to snugly match your facial contours. Use the included sandpaper to fine-tune it for comfort and safety.
Here’s the step-by-step process to ensure it fits just right:
- Begin by putting on the headgear.
- Hold the pancake helmet up to your face to assess the fit—don’t put it on yet, though. We’ll adjust it first.
- Press the hood firmly against your face and run your fingers over the top surface. You should feel no gaps or roughness where the balsa wood meets your forehead. Even the slightest unevenness could compromise safety.
- If you notice any bumps or rough patches on the forehead area, remove the helmet.
- Use the sandpaper provided to smooth out the surface gently until it’s perfectly even. Sanding balsa wood is straightforward due to its softness.
- Place the mask back on your face and continue sanding until the surface feels smooth and the fit is snug.
Getting the fit spot-on is crucial not only for comfort during extended wear but also for your safety. Remember, the design of the balsa wood box only concerns the upper curve for the forehead and not the lower curve, where it accommodates your nose.
After using pancake welding hoods for many years now, I can confidently say they strike the perfect balance of FUNCTIONALITY, PRACTICALITY, and COMFORT, especially for outdoor jobs like welding pipelines. They’re designed with clear visibility, top-notch safety, and efficiency in mind, making them a must-have in any welder’s toolkit.
However, one thing to note is that you can’t switch between auto-darkening and passive lenses in the same model, which can be a bit inconvenient. Despite this, many welders, myself included, prefer pancake helmets for specific welding tasks. I’ve used mine on various outdoor projects and have always found them more reliable and comfortable than traditional hoods.
Key Takeaways
Pancake welding hoods, inspired by George Gilchrist, offer a unique, round, and flat design that enhances comfort and visibility, particularly favored by pipeline welders.
These helmets provide good protection against UV rays, sparks, and debris, perfect for outdoor welding projects.
Ensure your pancake helmet meets OSHA and/or ANSI safety standards to guarantee top-tier protection and quality.
Benefits: Lightweight yet sturdy construction, comfortable for long-term wear, and excellent visibility for precise welding tasks, especially outdoors.
Limitations include incompatibility with conventional safety glasses and the absence of auto-darkening lens options.
Key parts of a pancake welding mask include the facepiece for protection, side shields for additional safety, and a balsa box for customized fit and comfort.
Consider factors like comfort, safety standards compliance, and specific welding needs when selecting a pancake welding hood.
