making a steel tab?

[section8joe]

I'm pretty new to metal working and I'm having trouble finishing up tabs. I can't seem to get my tabs to have completely straight edges. They all seem to be wavy. I also trace a socket on my tab corners to make rounded edges but they all look uneven. I'm using an angle grinder with a cut off wheel to cut the metal, then various flap wheels to finalize the tab. What can I use to get straight edges and evenly rounded corners?

 

[KenS]

A stationary belt/disk sander combo to finish the edges.

 

[bad_idea]

another vote for the disk sander. i use one all the time at work and love it. one of these days i will get one for the house. one of these days....

 

[tarbellb]

how big are you tabs?

if your using a socket, i wouldnt imagine much bigger then a 1" dia. if that the case you can:

use a hole saw bit, cut out perfect round circles, then cut them in half with your angle grinder. youll still have a small hole in the half circle, but its good for welding later.

its a lot of work, but you have some consistency.

* but i also vote on stationary sanding station- 6" belt + 9" disc combo. after i bought mine (used of CL for $125) i couldnt believe i went that long without.

 

[mike13u]

Trace outline on tab with Sharpie. Grind to line. File for final passes until desired look.

 

[gorilla]

The flap wheel is the wrong tool to get a flat edge, you should use a tool that has a flat surface like a stationary belt sander or a file. Lay your work out carefully with a scribe and work to the lines. You should also mark you radius out with a pair of dividers so that it's centered on the tab.

 

[Steevo]

A disk sander makes this MUCH easier.

Or, you can buy ready-made tabs from the chassis parts suppliers:
http://www.go-fast-parts.com/5709302.html
http://www.jerrybickel.com/chassis-tabs-and-mounts-1.html

 

[Larwyn]

A stationary belt and/or disc sander is probably the tool of choice. If there's much material to be removed, I'll get it close on the bench grinder and finish up on the belt or disc sander.

 

[section8joe]

I'm gonna give the file a try. I don't have s belt sander. I'll have to pick up a sander in the near future. Thanks guys...

 

[Rezarf]

I try to buy tabs and gussets... they take a ton of time to fab and can be bought cheap. AA manufacturing has a great selection.

 

[JonBoehman]

This is my go to place for most of my work.
http://www.welderseries.com/blog/online-store/category/handy-parts/

 

[mike13u]

Dont buy a tab. You need to learn this, even if you screw a few up.

This is very basic metal fab stuff and you are learning.

Take advantage of the experience and take pride in the finished product.

 

[paranoid56]

i would agree with above. this is basic fab that you need to learn. once you have goten that down. then buy tabs lol. at less then a buck a tab its not worth my time to make them.

 

[trbomax]

Like this.As it happened I was makeing 3 today for a snow plow upgrade.

 

[Alchymist]

This might give you some ideas:
http://bbs.homeshopmachinist.net/showpost.php?p=714498&postcount=1517

 

[gixer007]

This might give you some ideas:
http://bbs.homeshopmachinist.net/showpost.php?p=714498&postcount=1517

Thanks for sharing that link. Never thought of that one.

 

[crewchief888]

grinding straight lines and makig smooth transtions take patience and practice.
if you're using an angle grinder, use long, consistant strokes with the grinder.
the straighter the initial cut, the easier it is to finish.
ive thought about getting a belt/disk sander for a few years, but i always talk myself out of it. been using grinding wheels, and disks for many many years.

if you are making several mounts that are the same, cut them all out, clamp them in a vise and grind them all at the same time.

 

[KMinAF]

I buy mine from a local 4x4 shop (OffRoadDirect.com or similar) they are cheap, come in many different sizes and configurations plus they are laser cut.