Show us your welding projects

[ObnoxiousFumes]

I wish I hadn't mentioned it.

I'm glad you did! That's the kind of stuff I love to learn!

 

[PugetDude]

Even though it's odd, I enjoyed it.

 

[colindoyle]

I built this taller landing gear for my airplane (experimental/amateur built Fisher Celebrity) after finding out the hard way that it didn't have enough propeller clearance to land in a tail-high attitude, as one typically likes to do on hard surfaces. I took it from ~4" clearance to 18" clearance now with the fuselage leveled.

I worked from the outside in, first making these wheel hubs to mate 6" kart wheels to ATV brake rotors, then made caliper brackets and these clevis things, which will engage telescopic struts that contain bungee shock cord, like a Piper Cub. The shock cord is the 'spring.' The step milled into the clevis engages a matching step machined into the back of the axle shaft, allowing it to be retained in the spindle bore by one big bolt in the center (there's a video.)

It should make sense after the next post or two...

 

[colindoyle]

It's all 4130 chromoly tubing in the gear legs and cabane, and the axle shafts are 4340. TIG welded everything with ER70S2 filler rod.

I had some trepidation about extending the gear legs without increasing the width of their attachment points under the fuselage, as they're acting like a more effective lever now to twist their mounting bosses. I made a little cross brace that spans the rear pickup points and loads in compression against any forces acted upon the tires. Haven't made a carrier landing into a gopher hole to test it yet.

 

[colindoyle]

All assembled. I stuck the brake calipers upside down to shroud the hoses from damage when bouncing on a turf runway. Bleeding them kinda *****, but you don't have to do it with any regularity.

 

[Beerhippie]

Now for something completely different!

As in, 15-minute shade-tree fab/welding.

I needed a post driver as I had to sink an 8' ground rod for a lightning ground today. I didn't have a driver handy, nor an acorn that would fit my Bosch rotohammer. So off to the boneyard!

A 29" piece of 3" OD well casing--left over from a fence project years ago--and some random scrap of 1/2" plate, some grinding, some time making sparks and:



"Drive it like you stole it" was one of the mottos of a fencing crew I worked on years ago. The other ones aren't fit for a family-friendly site. I was reminded how long ago it was that I spent hours driving posts, but the rod is driven, wire is hung and that new antenna at the highest point of our tallest building at the brewery is now grounded. We had a real boomer come through Sunday night and I was feeling nervous about having an un-grounded lightning rod.

Anyone need to drive a few T-posts, you're welcome to borrow my driver. I'll bring the beer, a lawn chair and some advice.

 

[colindoyle]

I think you should put a bar clamp on top with some Renthals.

 

[Beerhippie]

Nah, handles on a post driver are for newbies!

Not that I intend to ever use it much!

Your work is AWESOME! I used to be a better welder than I am now, but never anything like that.

PS: Alaska Bushwheels used to be right up the road from me.

 

[colindoyle]

Thanks. I still consider myself a hobbyist, I don't have any certs or anything. Just been very self-critical and try to push myself to improve every time I flip down my hood.

 

[ObnoxiousFumes]

Place sounds pretty big, your own shop or is that your place of employment?
Stellar work as always!

 

[colindoyle]

I'm an indentured servant to a family business, so that line gets really blurry. (My name isn't on any property but a T-hangar lease.)

 

[Beerhippie]

I'm an indentured servant to a family business, so that line gets really blurry. (My name isn't on any property but my hangar lease.)

Sounds familiar, but it ain't my family.

 

[colindoyle]

Easier to extricate, hopefully.

 

[M.Brane]

+1 on the awesome work. Always enjoy reading your posts. Hope to figure out the whole TIG thing one of these days when I have the quality time to spend with the welder I bought a couple years ago. I can stick things together OK, but still in the hack stage.

 

[PugetDude]

I passed on the opportunity for a minority ownership interest in a family-owned business over 20 years ago. One of the best business decisions I ever made. Had a great career without any messy legal entanglements.

 

[colindoyle]

+1 on the awesome work. Always enjoy reading your posts. Hope to figure out the whole TIG thing one of these days when I have the quality time to spend with the welder I bought a couple years ago. I can stick things together OK, but still in the hack stage.

I just had to force myself to use the TIG when I would've much rather used MIG. Gotta accept that it's a slow process, but the results will be worth it eventually. Prep is huge - remove all mill scale, whether mechanically with a DA sander or pickling in muriatic acid, and then rinse in acetone before you even think about turning on the welder.

I'm still welding with the Lincoln Square Wave 175. When I get good, maybe I'll upgrade to something with more screens and dials.

 

[Beerhippie]

I'm using the same gloves. Why don't my welds look like that?

Asking for a friend.

 

[cycle61]

I'm using the same gloves. Why don't my welds look like that?

Asking for a friend.

You didn’t tig weld your fence post driver?

 

[Old Man Roger]

All assembled. I stuck the brake calipers upside down to shroud the hoses from damage when bouncing on a turf runway. Bleeding them kinda *****, but you don't have to do it with any regularity.

I didn’t sleep much last night, so I admit to not reading and just looking at the pretty pictures..lol But that bungie cord suspension scares me.

 

[colindoyle]

Pretty common design derived from the Piper J3 Cub. There's a positive stop to limit travel if the bungees snap, and they're supposed to be replaced on a calendar interval. The striped bands woven into the shock cord casing are color-coded to indicate date of manufacture.

 

[Beerhippie]

You didn’t tig weld your fence post driver?

Up until a few years ago, I TIG welded everything and very rarely pulled out the MIG--mostly for big structural things. Nowadays, it's the other way around, and I use the MIG for anything I can. Much faster set-up and prep and just easier all around. Not near as pretty, but then, my TIG welds weren't all that pretty at the best.

I miss the sanitary welding. Thin-wall 316L tubing, fitted to a gnat's *** and fusion welded with the tubing flushed and supported by argon. Done well, the welds almost disappear. Unfortunately, it requires very good eyes--joints fitted to a gnat's *** are hard enough to see without the welding helm--and very steady hands. I no longer have those. We hire our sanitary work out to a fellow who has family here and comes to visit for the holidays.

 

[Bob Heine]

I'm using the same gloves. Why don't my welds look like that?

I was thinking the same thing. I don't need a pair of gloves so I'm going to try using the extra one turned inside out. Maybe that will do the trick.

 

[harley jim]

 

[stinkity stoink]

More details on the trike. Looks like it’s going to be fun !!

 

[colindoyle]

Today's welding project... they can't all be bangers.

My dad went to use his little utility trailer today and found the coupler latch all blown apart due to a broken draw-down bolt (or whatever that thing is called.) I don't recall damaging it, but I probably hit it while plowing snow or damaged it while moving it around with the forklift. Must have been unaware or too swamped to deal with it, it's uncharacteristic of me to leave something damaged.

 

[kaymccampbell]

Today's welding project... they can't all be bangers.

My dad went to use his little utility trailer today and found the coupler latch all blown apart due to a broken draw-down bolt (or whatever that thing is called.) I don't recall damaging it, but I probably hit it while plowing snow or damaged it while moving it around with the forklift. Must have been unaware or too swamped to deal with it, it's uncharacteristic of me to leave something damaged.

Those perforated bolts stretch over time and finally fail. It's common.

 

[colindoyle]

Good to know!

 

[colindoyle]

EZGO Marathon I use around the farm. Stretched the wheelbase by building some framework under the seat that moves the drivetrain mounting points rearward, installed Suzuki LTZ400 front suspension and ATV wheels/tires, built a simple manual-dumping stakeside body, incorporated a 2" receiver hitch, built a front basket and installed a pair of old Meyer plow headlights. Pretty much all leftover material from other jobs.

I have a 2 cylinder Kubota diesel from a Carrier APU and a Yamaha G2 axle that I need to put in it... sick of dealing with the 2-stroke gas engine.

 

[LXCam]

Collin-brutha, I need a favor..


How bout you hold off for bit on sharing your awesomeness.

This here hack needs to melt this little mess together tomorrow and I’d hate to let the crowd down trying to follow you🫢


Thanks bro

 

[colindoyle]

Looking forward to seeing it!

 

[LXCam]

Looking forward to seeing it!

You’ll regret it..


And speaking of regrets, wtf was I thinking. Keep sharing bud, I’m stuck at a hotel and jonesing for more of your work

 

[colindoyle]

Keep in mind, I'm just sharing the highlight reel. Most of the junk I do is a lot closer to the trailer coupler than the airplane landing gear.

What are you constructing out of that pile of tubing?

 

[LXCam]

I’ve got a footprint issue in a horse **** technology room. I’m installing a little 15kva ups with an extended runtime battery cabinet. Problem is mounting them side by each like they’re supposed to be encroaches on the required clearance for some electrical panels. So this is nothing more than a stand to get the battery cabinet over the top of the ups.

 

[PugetDude]

Today's welding project... they can't all be bangers.

My dad went to use his little utility trailer today and found the coupler latch all blown apart due to a broken draw-down bolt (or whatever that thing is called.) I don't recall damaging it, but I probably hit it while plowing snow or damaged it while moving it around with the forklift. Must have been unaware or too swamped to deal with it, it's uncharacteristic of me to leave something damaged.

Hah! Finally something I can relate to.

 

[Bigblue&Goldie]

Colin, I'm impressed with the tig welds, but even more so with how nice you wrapped those mig welds! I wish I could use the glue gun half as nice.

 

[PugetDude]

You’ll regret it..


And speaking of regrets, wtf was I thinking. Keep sharing bud, I’m stuck at a hotel and jonesing for more of your work

Maybe he should offer it on pay-per-view?

 

[Nortonscustom]

Pretty common design derived from the Piper J3 Cub. There's a positive stop to limit travel if the bungees snap, and they're supposed to be replaced on a calendar interval. The striped bands woven into the shock cord casing are color-coded to indicate date of manufacture.

Did you use one or two piece kart wheels? Getting ready to build new bungy gear for my little Kitfox and picked up the same Carlisle tires. Looking at wheel options now.

 

[colindoyle]

They're one-piece Douglas 6" x 5" W with 2.5" backspace. I milled an additional three holes in each one because I didn't feel super confident having three 1/4-20 bolts holding my wheels on.

I got them from BMI Karts, part number was DWT706-04

 

[colindoyle]

Oh yeah... i found something stating the load rating of the Carlisle Turf Glide tires was 410 lbs/ea... my airplane is about 1,000 lbs with a full tank of fuel and me sitting in it; but I figure the wing is supporting the vast majority of the airplane's weight if you finesse the landing and 'fly it on,' until you're slowed and you let the tail down... and then you've got the tailwheel supporting some of the weight and you're rolling nice and slow. I don't know what load factor they designed into the tire before declaring it good for 410 lbs, but I'm going to try my best to achieve a tame rate of descent upon landing. I'm sure they didn't design this golf cart tire to accelerate from 0 to 60 MPH in a split second, either.

I saw a lot of Kitfox, Avid, and ultralight pilots using these tires so I figured I would throw caution to the wind and give them a chance.

 

[ObnoxiousFumes]

Maybe he should offer it on pay-per-view?

OnlyWelds?