Show us your welding projects

[neonnblack]

Didn't find a topic like this where everyone could share pictures of their good (or bad) welding/fab projects and maybe get pointers from other people. I'm hoping this doesnt turn into a **** fest if someone disagrees with someone elses procedures. So please, keep negative comments to yourself but share constructive criticism.

Nothing specific, ill start, even with me being embarrassed a bit about it. On with the pictures

Im a very begginer welder/fab person. I took metals in high school then dropped my motivation to continue it as a hobby, and maybe one day a career. I just started back up a few weeks ago and this was one of my first "projects".

Just a little square i made one day for practice:

This one had a large hole in the corner of it, and was one of the worse welds i did on the whole thing.

I never cleaned the welds either... oops.

I know not the greatest, but i dont plan on anything structural till i get a better welding unit so i figure its ok for now.

Now the welder i used, and you guys will hate me for this but...... It's a harbor freight http://www.harborfreight.com/welding/mig-flux-welders/90-amp-flux-wire-welder-98871.html

I have had it for about 4 or 5 years now. Using fluxcore wire... and its on about a 75 foot extension cord... I know i know it could change but it seems to be ok for now.

I use my HF 41/2 angle grinder to cut up the metal. Btw any suggestions on cutting and grinding disks?

Thanks for looking, post up your welding projects and gear.

 

[Cryo Gal]

That weld was with a FC wire? hmm. Well, practice makes perfect. Just start welding the **** outta everything LOL Is that SS, looks white in the pic? What kind of wire you using? Not that Im any guru, just learning with ya!

Abrasive wheels...not HF ;-)

 

[Nighttrain]

Great idea on the thread. Now that my garage is about done I am looking at knocking the dust off the stick welder that belonged to my dad. I would like to start with this and a torch then move up to a Mig. Ill be watchin this thread.

 

[xwarp]

good idea.

i've got one of little lincoln weldpak hd units. works pretty nicely and i'm learning as i am going.

 

[neonnblack]

That weld was with a FC wire? hmm. Well, practice makes perfect. Just start welding the **** outta everything LOL Is that SS, looks white in the pic? What kind of wire you using? Not that Im any guru, just learning with ya!

Abrasive wheels...not HF ;-)

Yep flux core, i cant tell if you mean that in they look good or could use some work, haha. either way any info on welding better with FC would be appreciated. And i am, i got a bunch of steel from work (its unused shelving systems btw not SS) Using .30 i believe im gonna buy a spool of lincoln or miller or a better FC wire to try as this is the HF wire. And this thread is mostly about learning and helping each other if anyone ahs a question.

 

[Neuswede]

Here's an engine cart I put together a few years ago for a Ford 1600 from a Lotus Super 7. I wanted to keep the engine portable, but have clearance to fit it under a workbench out of the way. I also didn't want to take a chance and have it tip over and mess up the Weber carbs, so this stand came about.

Some time later, I ended up selling the project car, then selling the motor to another buyer, provided I include the stand.

 

[frank1380]

This is a metal rod that functions as a bird feeder rod. Similar to this one at Amazon.com Essentially a long bar that hooks at the top and it has a support leg attached and you push it into the dirt. The little leg broke off and my dad asked me to weld it back on. I ran a bead like this down both sides. It was originally just tacked in one spot so it's not a real shock that it broke.

Fun and frustration all-in-one.

I'm not going to show any of my really ugly stuff and there is a LOT of it. My only welding experience was some light duty MIG welding to put new floor pans into my Beetle and my brother's Austin-Healey and that was 16 years ago.

 

[bauschracing]

This picture shows off two of my projects and one on the table in the works. I built this portable (movable) welding table out of 2" square tubing with a 1/8 top. There are crossmembers every 1 foot that are 1 1/2 square. Under the table are steps that serve a double duty. They act as a foot rest when welding and steps for getting in and out of the camper. These were miged using my Lincoln 180 Mig, but if you look, you will see my Westinghouse arc welder from the 1940's.
I am building a tubing bender on the table now.
Mike

 

[sberry]

Its hard to tell unless you flush it off a bit with the grinder but all in all it looks pretty good considering a few things. You could try a different wire but I doubt it make much difference, see what happens.

 

[justafurnaceman]

'81 Yamaha XS400 that I'm working on. Nothing too fancy. It's been a great learning project.

My little helper:

 

[Neuswede]

Yep flux core, i cant tell if you mean that in they look good or could use some work, haha. either way any info on welding better with FC would be appreciated. And i am, i got a bunch of steel from work (its unused shelving systems btw not SS) Using .30 i believe im gonna buy a spool of lincoln or miller or a better FC wire to try as this is the HF wire. And this thread is mostly about learning and helping each other if anyone ahs a question.

My biggest obstacle for me to getting better weld quality had nothing to do with wire or the machine, but light; or lack of it. If you can't see your work piece, your weld quality will suffer. As we age, our eyesight diminishes, so I use a magnetic worklight on the piece, which helps see the piece better prior to striking an arc. I also practiced alot with sheetmetal, mainly because it is fairly affordable and I had alot of it. Welding thin stuff helps you think about heat control and warpage, and the more practice you can do, the better chance you have of producing better welds.

 

[2manytoyz]

I'm new to welding, and bought a basic Lincoln MIG welder setup. I made a lightweight hitch for my riding mower, which allows me to move a utility trailer from the back of my property, up to the driveway, and vice versa. Saves me from having to drive the heavy truck across the septic tank or drainage field.

I took the setup to my buddy's house to let him try welding:

This setup allows the use of the original hitch too, which is often found on garden tractor carts (fork type).

I also used this to haul the BBQ grill to the patio when we moved into the new house. The grill does have wheels, but they don't work well on St. Augustine grass.

 

[SWT Racing]

I'm new to welding, and bought a basic Lincoln MIG welder setup. . .<snip>. . .I took the setup to my buddy's house to let him try welding:

I notice in a lot of the "in action" welding pics of newcomers to the MIG welding world that they are quite far away from the work and only using one hand. I always use two hands (if possible). . .one on the trigger and the other lightly supporting the nozzle in the gooseneck area. This allows more precise control of the gun for a consistent weld bead.

I also shove my helmet as close to the work as possible and still be able to focus my eyes so I can see exactly where the joint is and what the puddle is doing. We have to wear safety glasses at all times on the shop floor, and I've found that a good pair of clear/semi-mirrored safety glasses worn under the helmet will allow me to turn the shade down on my adjustable helmet and not get flash burn.

Keep up the welding! It is a great skill to have.

 

[xwarp]

why don't people weld without at least a long sleeve shirt and some gardening gloves or something?

i wear at least a sweat shirt and have some fireproof gloves when i do.

 

[Larwyn]

I have completed way too many fabrication projects to mention but here are a few of my favorites.

A receiver hitch for my lawn tractor
A cargo carrier for the tractor hitch
A stand for my slightly customized Horror Fright H/V bandsaw
A bicycle repair stand
A rack for the front of my '72 Raleigh Sports
A "mobilizer" for my weed burner

 

[cdseven95]

I notice in a lot of the "in action" welding pics of newcomers to the MIG welding world that they are quite far away from the work and only using one hand. I always use two hands (if possible). . .one on the trigger and the other lightly supporting the nozzle in the gooseneck area. This allows more precise control of the gun for a consistent weld bead.

I also shove my helmet as close to the work as possible and still be able to focus my eyes so I can see exactly where the joint is and what the puddle is doing. We have to wear safety glasses at all times on the shop floor, and I've found that a good pair of clear/semi-mirrored safety glasses worn under the helmet will allow me to turn the shade down on my adjustable helmet and not get flash burn.

Keep up the welding! It is a great skill to have.

Well he has no gloves on so I see why he is so far from the work! ... You learn to change those habits real quick though and start only welding with gloves... Oh and to the guy in the picture jeans do NOT stop slag and think of how you are sitting and WHAT is closest to the work.... PAIN!

 

[neonnblack]

Nice nice nice, i like the way this is going.

Nue: I agree with you with the light, i have to weld in the middle of the day or else i cant weld worth a damn. funny you mentioned that. The HF machine isnt a bad little machine though, it seems.

And i usually wear short sleeve shirt while welding, and depending on what im welding, ill wear welding gloves or not. I couldnt possibly hold a torch with one hand, im far too shaky. Normally if im standing, gun is in right hand, with my left hand holding my right from the top, with a little downward pressure.

 

[xwarp]

i've done a couple of welding repairs that i believe required some patience and steadiness.

in the first pics in this thread, and i am guessing because i am learning, is all that "over splash" or whatever it's called due to the welder being set too hot?

one of my repairs was welding an upper door hinge to the body side. unfortunately, these hinges are originally welded, but not where they should have been. the body obviously is thinner than the hinge so burning through the body metal while penetrating the hinge was a concern. luckily for me, i remembered that the body has a nice 1/4" plate behind the sheet metal to support the hinge so i ended up doing a decent job on that repair.

one thing i can state is that practice on spare metal. steel wheels are good too.

one thing i've learned, you have to move steady and consistent and you gotta get close to see your work.

 

[Yotaforce]

I weld according to the weather conditions.
Summer-100 degree heat and a fan blowing hot air around the shop=flip flops, shorts, tank top (which leads to sunburn, and spatter burned toes)
Winter-I'll start out dressed pretty warm, but anyone who welds on something long enough knows how hot it gets, so it migrates back to the tank top. Lol.
Here's something I finished up recently:
http://blog.diverse-customs.com/2011/08/1988-toyota-4x4.html

I hope all the pics show up. Google seems to be dicking around with stuff that ain't broke.

 

[neonnblack]

Nice tilt bed build yota.

And Xwarp the extra splater can be from numerous things, in my case i believe i had to much wire out of the tip i.e. should stay near 1/2 i was prob more towards 3/4 or 7/8 or so. Flux core wire naturally produces more also.

 

[xwarp]

Nice tilt bed build yota.

And Xwarp the extra splater can be from numerous things, in my case i believe i had to much wire out of the tip i.e. should stay near 1/2 i was prob more towards 3/4 or 7/8 or so. Flux core wire naturally produces more also.

cool, that is good to know.

 

[Neuswede]

Nice nice nice, i like the way this is going.

Nue: I agree with you with the light, i have to weld in the middle of the day or else i cant weld worth a damn. funny you mentioned that. The HF machine isnt a bad little machine though, it seems.

And i usually wear short sleeve shirt while welding, and depending on what im welding, ill wear welding gloves or not. I couldnt possibly hold a torch with one hand, im far too shaky. Normally if im standing, gun is in right hand, with my left hand holding my right from the top, with a little downward pressure.

Hey Neon: next time you have a chance, put on your welding helmet and the use a work light to light up a work piece. You will quickly see what you may have been missing. It has been a huge help to me and was a simple tip I got from a friend who has welded for years and has the same aging eyes I have. Great thread idea BTW.

+1 And for anyone new to welding, comfortable gloves and at least leather sleeves will help you get much closer to the work piece as suggested earlier. Even on the hottest days, I still use a coat and gloves.

+1: Putting yourself in position to use 2 hands will improve your weld quality very quickly.

 

[neonnblack]

Ill be trying that today, i have a legit project starting after i go to breakfast.

 

[zmotorsports]

Way too many to show all but here are a few of my more recent projects.

Mike.

Sandrail chassis, beginning with fabricating the chassis table and then the chassis.

One of my MIG welds from the sandrail chassis.

One of my TIG welds from above chassis.

Chassis back from powdercoating.

Sandrail completed and ready to hit the sand.

A couple of miscellaneous TIG welds.

Bumper I built for my Jeep to assist with better approach angle and incorporate tow points to tow behind our coach.

Finished bumper.

Rear sub-frame that I built for my sons sand quad.

After chrome and installation on quad.

Sand quad chassis made from 4130 chromoly. Engine is out of a GS1100 sport bike.

Completed quad.

 

[ert01]

Definitely use a bright work light to illuminate the weld area when youre first learning. It helps SOOOO much when you can actually see

Also get a thick set of tall leather gloves and use two hands. I rarely weld one handed and thats only when I'm in a really bad position and a tight spot.

Also since no one mentioned it, you're polarity should be reversed when you are using flux core wire. This only matters on welders that can do both gas and flux core so if you have a FC only machine then don't worry. If you have a mig machine and you are using flux core then read the manual and make sure it's reversed. This will help with the spatter for sure.

And make sure you prep the metal! Rust and paint are weld killers. Clean it good before you start. Even a lot of the new metal you buy (around here anyways) is coated in a grease or oil to stop rust during shipping and storage so clean that off too with a degreaser or something.

And an auto tinting helmet is wonderful when you're learning (in my opinion).

 

[richtersrodz]

I keep subscribing to these threads.. cause one day, I plan on learning to weld..

 

[Jim Stabe]

Definitely use a bright work light to illuminate the weld area when youre first learning. It helps SOOOO much when you can actually see
...
And an auto tinting helmet is wonderful when you're learning (in my opinion).

I agree that being able to see is critical but I have a question. Have you found a good way to have bright illumination of the work without triggering the helmet darkening?

 

[metaleltr]

1st and 2nd pictures
Sawhorses that I just fineshed a few weeks ago,built 4 of these frames, need to get 4x4s to bolt on top.

3rd and 4th pictures hose reels that I built in 8th grade.

5th picture shelf brackets i made 9th grade, yet to be installed.

6th and 7th pictures are of a contriol panel on a ranger tire changer.
The plastic one broke so I went to town fabricating a new one. The bolts are threaded into weld nuts installed with a air powered squeeze type resistance spot welder.

 

[ert01]

I agree that being able to see is critical but I have a question. Have you found a good way to have bright illumination of the work without triggering the helmet darkening?

I havent found it to be an issue using just a regular 300w or 500w halogen worklight as long as there are no really reflective surfaces but I do also use a cheap led headlamp sometimes too. I use a 3M speedglas helmet though so maybe it's not as sensitive to ambient light and reflections as others? I always set the lamp up behind me and over my shoulder so Im never looking at the bulb.

I'll take a picture of my welding setup and post it later tonight to show you my lights.

 

[Jim Stabe]

I havent found it to be an issue using just a regular 300w or 500w halogen worklight as long as there are no really reflective surfaces but I do also use a cheap led headlamp sometimes too. I use a 3M speedglas helmet though so maybe it's not as sensitive to ambient light and reflections as others? I always set the lamp up behind me and over my shoulder so Im never looking at the bulb.

I'll take a picture of my welding setup and post it later tonight to show you my lights.

Thanks

 

[Neuswede]

I agree that being able to see is critical but I have a question. Have you found a good way to have bright illumination of the work without triggering the helmet darkening?

Yes, I use a simple florescent work light with a magnetic base. It lights the piece but has no effect on the helmet. I am using a Speedglas helmet. The hard part is getting the gun, your hands, your head and the light all in a good position without interfering with one another. Sometimes, it's like being Gumby, but rarely do I weld with only one hand; almost always with 2.

 

[muibubbles]

Fun and frustration all-in-one.

I'm not going to show any of my really ugly stuff and there is a LOT of it. My only welding experience was some light duty MIG welding to put new floor pans into my Beetle and my brother's Austin-Healey and that was 16 years ago.

mig or tig? i assume tig? or are you welding alum with a mig?!?!/ ohh the confusion!

 

[frank1380]

mig or tig? i assume tig? or are you welding alum with a mig?!?!/ ohh the confusion!

Sorry about that, it's TIG. I only had any experience with a MIG welder many years ago. I'd never even seen a TIG machine before I'd bought mine. So needless to say I'm self taught with some advice from my brother-in-law.

 

[SWT Racing]

Here's a water-to-air intercooler I did about 8 years ago, along with the mounting base from 4130. I made it with an integral water reservoir, integral submerged water-to-oil transmission cooler and attached the water pump to the base. It all fit onto the factory seat mounts for a Fox-body Mustang. I believe it made 1177RWHP with a 302 and an 88mm turbo.

It eventually split a seam at 32psi of boost, so I later reinforced all the seams. The plugs in the inlet/outlet were for pressure testing.

 

[SWT Racing]

Well he has no gloves on so I see why he is so far from the work! You learn to change those habits real quick though and start only welding with gloves...

True. I usually will use a TIG glove (or thinner leather glove) on my trigger hand and a MIG glove on my support hand. Since I'm usually in short sleeve shirts, I'll throw on a pair of flame retardant sleeves. . .not that I don't have permanent track marks on my arms from hot weld "cherries" burning through the sleeves.

Oh and to the guy in the picture jeans do NOT stop slag and think of how you are sitting and WHAT is closest to the work.... PAIN!

Quoted for truth. Let's just say when I was fairly inexperienced in such matters many years ago, that I was sitting on a sill bar welding a gusset on a roll cage. Well, I was wearing jeans that had a hole in just the right spot to allow hot molten metal to burn me in a most sensitive place. I learned REAL QUICK after that!

Much more painful than the "up-the-nose" or "ear canal" cherries!

 

[merlinpro]

neonnblack...

I have the same welder as you!

The first thing i did was to get rid of the wire that comes with the machine, Then i went to home depot and purchased "Lincoln" 0.030 FC wire and what a huge diff!!!

Your welds arent that bad, but will improve with the new wire,,,trust me!

This afternoon i just picked up my new welder

Today i purchased:

Millermatic® 211 Auto-Set™ with MVP™

60 cft argon/co2 bottle

Radnor autodark helmet

I'm speechless...only used it for about 10 min and its incredible!

 

[ert01]

I also have the same Miller... 211 AS with MVP. I had a Miller 251 before but it was much too large for my small garage and I never pushed it anywhere near its limit so I sold it off and bought the 211 and a spool gun kit and some aluminum wire and a couple bottles.

I could care less about the Autoset feature, but the multi voltage is very nice for a small(ish) and more portable unit. I actually use it quite a bit. I also like the smaller gun on the 211 vs the bigger one on the 251. I know the 251 is much more industrial and durable, but I can fit this one in the more awkward spots on my Jeep much easier.

 

[ert01]

Here's my welding cart setup and my work lights. Please excuse the mess of cables... They were tidy at one point in time

I can't take credit for the cart design. I saw a picture of it on the Internet somewhere and adapted it to suit my own needs a bit.

Made the light myself too but that's the easy part since I'm an electrician and I got all the parts for free from work.

 

[neonnblack]

neonnblack...

I have the same welder as you!

The first thing i did was to get rid of the wire that comes with the machine, Then i went to home depot and purchased "Lincoln" 0.030 FC wire and what a huge diff!!!

Your welds arent that bad, but will improve with the new wire,,,trust me!

I actually did do that this morning since i was running low on wire anyways. I picked up .035 this time though havent really tested it yet, this weekend i will.

 

[hunter1151]

Did that guy have a pack of smokes in his short sleeved shirt.........I just hope there wasn't a bic type lighter in there with them.