a gap welding process for manipulating a movable robotic welder for making a weld between two or more substantially immovable work pieces using a higher level programming language . the gap welding process performs a data transfer routine which takes spreadsheet data representing expected variables , runs a data conversion program that creates weld program data including point position , user frames , weld schedule , seam tracking schedule , weave schedule , azimuth orientation , travel speed , wait time , weave type and number of digital output control data . the gap welding process also performs a gap - sensing routine for actual weld gap measuring by using the robotic welder to touch specific locations on pieces forming the gap or fixturing to produce weld variance data . the gap welding process then uses a weld control program in conjunction with the weld program data , weld variance data , and feedback data that is gathered during the welding process to determine and perform the correct manipulation required to produce torch movements to accurately weld the gap .