A gap welding process (10) for manipulating a movable robotic welder (30) for making a weld between two or more substantially immovable work pieces (51) using a higher level programming language (20). The gap welding process (10) performs a data transfer routine which takes spreadsheet data (18) representing expected variables, runs a data conversion program (20) that creates weld program data including point position, user frames (34 and 36), 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 (10) also performs a gap-sensing routine (28) for actual weld gap measuring by using the robotic welder (30) to touch specific locations on pieces forming the gap or fixturing to produce weld variance data. The gap welding process (10) then uses a weld control program in conjunction with the weld program data (22), weld variance data (26), and feedback data (44) that is gathered during the welding process to determine and perform the correct manipulation required to produce torch movements to accurately weld the gap (32).