Show us your welding projects

Brian_B_ · Jun 5, 2012

Again not a project and certainly nothing that takes any skills.

I have seen many professional and home made air tool racks. I found where someone machined some out of aluminum that I liked the design. So..I borrowed the idea. I do not have access to a milling machine. I do not like having to use both hands to get an air tool off a rack (the quick connects). That works great, but I'm lazy.

Mine are some scrap metal with slots punched and bent on a press brake. I didn't pay attention to the GA of the metal...maybe 18 or 20? When they are formed...they very stiff. No need for heavy GA material.

One note: The slots in the face..are wider than the ones the tools actually hang from. That way the quick connect fits through the front.

ME87 · Jun 8, 2012

attached the tray I made for the direct TV box that I welded together this afternoon. It bolts in place of the factory TV stand.

Wanna Ride · Jun 8, 2012

The bike lift originally only came with a 20" ramp, but I needed one that was about 36"....

Brian_B_ · Jun 8, 2012

I have a lot of paint brushes that were given to me. Some new some used..they were getting ruined laying around....so more scrap~!

slow50 · Jun 8, 2012

steel 35 said:
Dueling targets not much welding and its not pretty! Stainless tubing notched and it works pretty well with 22s and a few handguns don't know where the 1/4" limmit is yet?

those are cool i need to make one. do you just stab them into the ground?

F-117HWK · Jun 12, 2012

Where would yall recommend buying my first welder?
I want to check out some local weld places first, but I have seen Cyberweld.com as one of the most popular online places.

I am pretty much set on a Miller 211. I need the 120v at the moment

Then I need a helmet (Miller Digital Elite).

What would yall recommend for a bottle setup? 75/25 mix Argon/Co2 seems to be the most popular. Is it 2 separate bottles then regulator valve for the correct mix?

.30 wire? (any wire recommendations?)

Gloves?

Anything else?

(this will be for weekend welding projects, tables, roof racks, headache racks, etc with a tube buggy way down the road)

bggrnchvy · Jun 12, 2012

F-117HWK said:
Where would yall recommend buying my first welder?
I want to check out some local weld places first, but I have seen Cyberweld.com as one of the most popular online places.

I am pretty much set on a Miller 211. I need the 120v at the moment

Then I need a helmet (Miller Digital Elite).

What would yall recommend for a bottle setup? 75/25 mix Argon/Co2 seems to be the most popular. Is it 2 separate bottles then regulator valve for the correct mix?

.30 wire? (any wire recommendations?)

Gloves?

Anything else?

(this will be for weekend welding projects, tables, roof racks, headache racks, etc with a tube buggy way down the road)

I bought my MM175 from Cyberweld, I was content, but the current tig and future welders will come/have come from classifieds.

A Miller Elite is an excellent choice.

With a bottle my first bit of advise is get a bigger one. Doesn't matter what you think you can scoot by on, get a bigger one, they're cheap. I got an 80cu.ft. for my mig, I can't keep it filled seems like. The 160cu.ft. for the tig was ~$180 outright filled with Ar, cheap.

As for gas, yes 75/25 (C-25) is the most common hobbyist shielding gas, it comes in a single bottle premixed. All you do is set the flow rate on the single regulator.

You mean .030 wire. .030 solid core is a pretty good all purpose diameter for home related and light duty vehicle fabrication. A small 2lb roll of .023 on hand for the odd 22ga sheetmetal project is nice to have though.

F-117HWK · Jun 12, 2012

bggrnchvy said:
I bought my MM175 from Cyberweld, I was content, but the current tig and future welders will come/have come from classifieds.

A Miller Elite is an excellent choice.

With a bottle my first bit of advise is get a bigger one. Doesn't matter what you think you can scoot by on, get a bigger one, they're cheap. I got an 80cu.ft. for my mig, I can't keep it filled seems like. The 160cu.ft. for the tig was ~$180 outright filled with Ar, cheap.

As for gas, yes 75/25 (C-25) is the most common hobbyist shielding gas, it comes in a single bottle premixed. All you do is set the flow rate on the single regulator.

You mean .030 wire. .030 solid core is a pretty good all purpose diameter for home related and light duty vehicle fabrication. A small 2lb roll of .023 on hand for the odd 22ga sheetmetal project is nice to have though.

Thanks for the reply.

For some reason I want to purchase my first welder brand new. I think once I am more comfortable with everything, I will start looking for deals in the classifieds and such for a TIG or other supplies.

The Elite seemed to be the most recommended, and I highly value my eyesight, so I dont mind the extra cost over some of the other auto helmets.

For the bottle, I agree bigger is better. How big dimension wise is a 160cu.ft bottle? Would the local welding shop probably be the best place to pick that up? Cyberweld will send a brand new bottle fully filled, but it looks like they only have up to 80 cu.ft for $200

Learn something new every day. I never realized that the mix was in the same bottle. :beer:

Yes, forgot a 0 in there. That would be some big wire :lol_hitti

Maybe I will grab another size down the road for some other stuff.

Thanks again.

bggrnchvy · Jun 12, 2012

F-117HWK said:
Thanks for the reply.

For some reason I want to purchase my first welder brand new. I think once I am more comfortable with everything, I will start looking for deals in the classifieds and such for a TIG or other supplies.

The Elite seemed to be the most recommended, and I highly value my eyesight, so I dont mind the extra cost over some of the other auto helmets.

For the bottle, I agree bigger is better. How big dimension wise is a 160cu.ft bottle? Would the local welding shop probably be the best place to pick that up? Cyberweld will send a brand new bottle fully filled, but it looks like they only have up to 80 cu.ft for $200

Learn something new every day. I never realized that the mix was in the same bottle.

Yes, forgot a 0 in there. That would be some big wire
Maybe I will grab another size down the road for some other stuff.

Thanks again.

The footprint on the 160cuft (S) cylinder is about the same, it's just taller. As I recall I think the S cylinder is ~8" OD and ~50" tall, whereas the 80(Q)cu/ft. is ~8" OD and 30" tall.

Botje · Jun 13, 2012

Some various welding stuff that i have online on other forums:

downpipe for my car when i installed the turbo. 321 stainless steel bends, 3".

making an intercooler fit, shortened the end-tanks and welded on new brackets.

welded bung for wideband 02 sensor on exhaust for another car.

Firefighter315 · Jun 16, 2012

F-117HWK said:
How big dimension wise is a 160cu.ft bottle?

bggrnchvy said:
The footprint on the 160cuft (S) cylinder is about the same, it's just taller. As I recall I think the S cylinder is ~8" OD and ~50" tall, whereas the 80(Q)cu/ft. is ~8" OD and 30" tall.

Both the 80 and 160 cf cylinders were 7" diameter when I spec'd them both out a while back. This held true with several vendors. Height on the 160 was within an inch or so of what is noted above.

illmatyk · Jun 16, 2012

Botje said:
Some various welding stuff that i have online on other forums:

downpipe for my car when i installed the turbo. 321 stainless steel bends, 3".

Are both those widebands wired together or have 2 separate connectors? ( I only see one in the pic ). Nice work too!

jlmccuan · Jun 17, 2012

I believe the one on the left is EGT and the one on the right is O2

F-117HWK · Jun 18, 2012

bggrnchvy said:
The footprint on the 160cuft (S) cylinder is about the same, it's just taller. As I recall I think the S cylinder is ~8" OD and ~50" tall, whereas the 80(Q)cu/ft. is ~8" OD and 30" tall.

Firefighter315 said:
Both the 80 and 160 cf cylinders were 7" diameter when I spec'd them both out a while back. This held true with several vendors. Height on the 160 was within an inch or so of what is noted above.

Thanks for the info. Where are yall getting your cylinders from? My local place, Robert's Oxygen, only sells 80cuft for $195 with a free fill the first time, then $65 after that. They have 141cuft tanks as well but only for rent.

I can get a brand new 80cuft tank from cyberweld for $199 shipped to my door full with the welder.

Should I keep looking around?

Brian_B_ · Jun 18, 2012

A borrowed idea..with magnetic bowls added.

steel 35 · Jun 20, 2012

slow50 said:
those are cool i need to make one. do you just stab them into the ground?

I started like that but after my neighbor nurse lady started ringing the dam things I had to make them a little stiffer. And yea there fun.

zmotorsports · Jun 21, 2012

I am not one to like working on boats but a guy called the other night needing a small welding job done on the 1964 StarCraft that he is restoring. I had some time between other jobs so I had him bring it by the shop.

After lying on my back getting all of the fiberglass cloth/tape/resin removed I had a "light bulb moment". I will just pick up the trailer and the boat with the two-post lift and weld standing up rather than lying on my back. It worked out great and the boat/trailer actually balanced very well. The boat was gutted so I don't think the boat and trailer combined weighed more than about 700-800 pounds.

Mike.

Boat on the lift.

Aluminum pounded back into shape/position and welded from the bottom.

I also made some small patches that were about an inch larger than the repaired areas from 1/8" aluminum and welded them over the top on the inside. I radiused the corners as to not create stress risers.

Wanna Ride · Jun 21, 2012

Brian_B_ said:
A borrowed idea..with magnetic bowls added.

I'm digging it! Next project on my list for my bike table/lift.

Silver6.0 · Jun 22, 2012

Built this this morning, paint gun holder for my new guns.

BD1 · Jun 22, 2012

Silver 6.0 Your not gonna use them are you ???????????????????

Those should be for display only ! Nice job.

ME87 · Jun 24, 2012

Built a stand for my new H.F. Bench top blaster.

WakonTonka · Jun 24, 2012

About that blaster table-it looks like it came with the blaster, nice job with the sizing of the angle and overall dimensions!! :rocker:

NASTYZEN · Jun 24, 2012

Lots n lots of nice projects guys.
Here's a last minute repair job I had to turn around in a hurry for this weekends local races.
A baffed primary header pipe from an old Reynard Formula Ford.

I was going to replace the first part made of 1 3/8 tubing because it was so worn out and had been welded on so many times before. But had only 1 1/2 in stock and no time to get or make more.
A weekend patch repair it is then. First I cleaned up the weld area and welded the cracks up.
Using the 1 1/2 U bend I crafted a patch by splitting it it half with the band saw and fitting it to the pipe.

I do most of my thin gauge fish mouth cutting using tin snips.

Ready for some action.

Wanna Ride · Jun 24, 2012

Nice repair, and improvement!

WakonTonka · Jun 24, 2012

Dude you are one with your weldmuse

e-tek · Jun 24, 2012

Nastyzen - was that with the mig - or gas?

zmotorsports · Jun 25, 2012

e-tek said:
Nastyzen - was that with the mig - or gas?

Looks like TIG but could be a neat and tidy gas weld. Hard to tell after bead blasting or wire wheeling the HAZ off.

Mike.

NASTYZEN · Jun 25, 2012

Sorry,forgot to spec things.
Tig welding it was.
5/32'' Dia. thoriated ground electrode.3/8 Dia. shielding cup and I used .032'' Dia. filler rod from my mig. Argon gas at 12cfh.
There was a coat of spray galvanized protector on it. I suspect that that was the main problem when they first fixed it without removing that **** first.
The zinc contaminates the base metal and makes it hard as hell to weld it.Not to mention what it does to your lungs......
I first wire brushed it the best I could with the twist wire type brush then sanded it with 120g paper to get the coating off. It was so thin that I dare not grind it off. A little was left ,so that's why the weld is not as pretty where there's welding on the perimeter.
I finished it all off with the same twist wire brush after welding and used a die grinder with a carbide radius end to finish the inside.

mscribellito · Jun 25, 2012

This thread inspired me to buy a welder. Just a small Northern Tool Flux Core I got for ~$120 after the sale and coupon.

Small welding cart i built this weekend. I plan to add something for the cables sometime this week. I also chose to bolt the casters on just in case I had to replace one.

This is my first "real" project with my welder. I plan to get a MIG welder soon

zmotorsports · Jun 25, 2012

mscribellito said:
This thread inspired me to buy a welder. Just a small Northern Tool Flux Core I got for ~$120 after the sale and coupon.

Small welding cart i built this weekend. I plan to add something for the cables sometime this week. I also chose to bolt the casters on just in case I had to replace one.

This is my first "real" project with my welder. I plan to get a MIG welder soon

Looks great. With a welder the projects are never ending. Keep the pictures coming as your projects unroll.

Mike.

T.Hadley · Jun 25, 2012

My newly acquired commuter car had cheap plastic cup holders that were broke, they wanted 45.00 for a replacement so I made my own.

e-tek · Jun 25, 2012

Now THAT's a cup holder!!!!!!!!!!!!!!

Definitely NOT made in China!

zmotorsports · Jun 26, 2012

^^^^Nice. Great job on the cup holders.

Mike.

zmotorsports · Jun 26, 2012

I had a little time in the shop last night so I fabbed up two quick jobs that I have been meaning to do.

First was a holder to hold the windshield for my H-D Dyna Wide Glide when it is not on the bike.

First I marked some 3/4" square tubing for 16" centers to mount to the studs.

I then drilled some holes for the grabber screws to mount to the wall. I drilled a 5/32" hole all the way through and then a 5/16" hole in the outer section only for the head of the screw to pass through. I think this makes a cleaner looking mount when you don't see the screw head on the outside of the tubing. I also think it mounts to the wall a little more securely.

Completed and mounted.

I guess I forgot to take a picture of it on the wall holding the windshield. I will get a picture of that tonight and post.

Here is the next project that I threw together last night. I have a Toyota 3.4 litre engine coming in this weekend to replace the timing belt and water pump on. Snap-On makes a tool that compresses the hydraulic tensioner which eliminates the need to remove the A/C compressor and save a lot of time. I could not get a tool quick enough for the job coming in so I just fabbed one up last night.

It spans between the water pump pulley and the tensioner. The threaded nut will push the opposing saddles away which will compress the tensioner until the retaining hole is exposed and secured. I have seen people damage these by threading the tool too quickly and not allowing enough time for the oil to expel from the tensioner through the orifice but if you thread slowly they work great.

Here is the finished product.

Here is one of the welds.

Here is another weld. Sorry this picture was a little blurry.

I left the tube a little long so once I get into the job I can cut that to length as I didn't have the exact length upon time of fabrication.

Mike.

WakonTonka · Jun 26, 2012

That tool will make Snap-On jealous. As always nice tidy work!

V-10 Killer · Jun 26, 2012

Damn, all these awesome projects finally shattered my willpower.
I finally broke down and ordered my first welder (Everlast PowerPro 205) and got the tank and filler rods today...
Only 1,000,000 practice welds to go and I'll have something worth posting too lol.

welder4956 · Jun 26, 2012

T.Hadley said:
My newly acquired commuter car had cheap plastic cup holders that were broke, they wanted 45.00 for a replacement so I made my own.

Hmmmm...that looks so familiar.

T.Hadley · Jun 26, 2012

LOL @ WELDER

Yeah us mustang guys are everywhere

mtnkrake · Jun 26, 2012

Fire place toolholder. Not much welding came out OK.

zmotorsports · Jun 26, 2012

WakonTonka said:
That tool will make Snap-On jealous. As always nice tidy work!

Thank you. I appreciate that. The Snap-On one would definately be nicer I think but the price was right on this one. A little scrap metal and a half an hour was a good deal.

Mike.

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