Show us your welding projects

[Mustang67ford]

Out of curiosity, what is the majority of this welding done with, tig?

I have an arc welder and a a set of torches. I can never get that good of results with the arc not can I weld thin stuff.

With the torches, I can weld thin stuff but most of the time, like with bolts, the metal is so junky, my welds don't hold. If it doesing hold, then I result to the brazing rods.

 

[Nerdcore]

Bend test or x-ray?

X-ray. Next week I'm doing a stainless and aluminum TIG cert. it will be 1F and 6G pipe.

 

[jhn9840]

Nlce Looking vertical up Nerdcore.

jhn9840
John

 

[Case IH]

I don't have any pictures of projects, but I have my vertical up MIG certification plate.

Is it just the pic. or is the joint not fully filled in/capped?

 

[welder4956]

X-ray. Next week I'm doing a stainless and aluminum TIG cert. it will be 1F and 6G pipe.

Sorry to hear that. Ask your instructor if x-ray is permitted for GMAW short circuiting mode under AWS D1.1 or ASME Section IX and see what he has to say. Hint: It is not permitted for GMAW-SC. I asked because they have about a 75% failure rate on bend tests, but will pass x-ray because the lack of fusion areas are so hard to detect.

Your technique looks great though. The main thing on vertical is to hold the sides long enough to get good penetration and keep the wire on the leading edge of the puddle.

 

[Duker]

I do finishes like that using paint so it wouldn't surprise me if that was.

Your other option is using patinas.

http://www.metalartistforum.com/maf/index.php?/forum/6-patinas/

http://www.sculptnouveau.com/

Thanks for the links. There is some interesting threads on techniques and finishes.

 

[Duker]

Thanks! I rusted it with Muriatic acid and sealed it with urethane

Interesting, I will have to try out some test pieces. Thanks for the info.

 

[Nerdcore]

Is it just the pic. or is the joint not fully filled in/capped?

It was 3 passes. I don't have a picture of the third pass handy.

 

[Nerdcore]

Sorry to hear that. Ask your instructor if x-ray is permitted for GMAW short circuiting mode under AWS D1.1 or ASME Section IX and see what he has to say. Hint: It is not permitted for GMAW-SC. I asked because they have about a 75% failure rate on bend tests, but will pass x-ray because the lack of fusion areas are so hard to detect.

Your technique looks great though. The main thing on vertical is to hold the sides long enough to get good penetration and keep the wire on the leading edge of the puddle.

I'll have to ask. I haven't gotten my papers yet but I was told I passed. I assumed it was X-ray by the way they talked about it. But nothing was really laid out there about it.

 

[ImLow78]

I too am a huge fan of the Dynastys, I used one at school last year but am stuck with a POS EconoTig at work....bummer

Yes, the Dynasty will spoil ya!

I don't have any pictures of projects, but I have my vertical up MIG certification plate.

Nice looking vert. What matiral was yours on? 1/4" or 3/8? Here is one of mine on 1"x4" plate (Yep, I still need to work on mine).

Shannon

 

[sberry]

These are just demo to show how to carry the heat, hey are not poster perfect. The third one here is a girl after about 45 minutes wrk on the machine, was trying to get her to lay this big fattie in a single pass while washing the root in. In 4th pic she got consistant but hi in the center, needed to flatten it out.

 

[Cobra4B]

I'm a noob at welding, but it's something I've always wanted to learn how to do. I'm rebuilding my father's Panoz racecar and stripped it down to the bare chassis to get it powdercoated gloss white. Decided to fill up all the random holes that had accumulated over the years as a patched and band-aided ex-driving school car. The old heat shielding was riveted on panels. I'm upgrading to DEI floor/tunnel shield so all the holes got filled. I also did some basic updates like a new dash panel, a proper harness bar, and new brackets for the cut-off switch and fire bottle pulls.

http://sphotos-b.**.fbcdn.net/hphotos-snc7/3170_4259837585415_1778662496_n.jpg
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[Nerdcore]

Yes, the Dynasty will spoil ya!



Nice looking vert. What matiral was yours on? 1/4" or 3/8? Here is one of mine on 1"x4" plate (Yep, I still need to work on mine).

Shannon

You're moving up too high. You should be doing a Z pattern. Go across and then up across and up. Don't move the wire out of the puddle either. Mine was 3/8 plate.

 

[Nerdcore]

These are just demo to show how to carry the heat, hey are not poster perfect. The third one here is a girl after about 45 minutes wrk on the machine, was trying to get her to lay this big fattie in a single pass while washing the root in. In 4th pic she got consistant but hi in the center, needed to flatten it out.

That last picture. I know it can't be. But that looks a LOT like globular. Need to hold the sides more.

 

[zmotorsports]

Had a small welding job come through the door last night. A guy had two brackets that he needed an inch cut out of to shorten them up. Not a big job but I haven't MIG welded in a while so I thought I would throw up a few pictures.

Mike.

Here is what the bracket looked like before cutting it down.

Here is 1" removed from the overall height.

Notched and pressed back together.

Underside ready to weld. Prior to pressing back together I took a Roloc disc and ran it over the metal to remove the galvanizing.

Welding completed.

Completed with removed section. All that was done prior to customer picking it up was I bead blasted the part and sprayed it with some cold galvanizing.

 

[kazlx]

Looks good. Did you weld the underside or just the top?

 

[zmotorsports]

Looks good. Did you weld the underside or just the top?

Thank you.

Yes, I welded the underside and then flattened it off on the disk sander prior to bead blasting and cold galvanizing.

Mike.

 

[TimeWarpF100]

Will have to dig up more pics but here is a set of Headers I built for a Cobra.

No fancy cutting table or plasma so had to cut the flanges out freehand with torch. Best part was it gained 100HP on chassis dyno compared to what was on it. ALso a pic of what it looks like today. SOme may recognize the car.

How about 1500+ HP? (Total in the 3)

Best part is Boyd Coddington had about ZIP to do with this car other than wanted his name on it. I did end up making another set of headers for a Cammer Cobra Project for Boyd before his passing. Dont remember the Dyno numbers but it was HUGE gain in power.

Edit add: I just read through the kitcarmag article. About 2% of what they say is true! Total bogus story. The chassis as pictured when I did headers was DONE, The pipes were powdercoated etc before Don Borders even saw the car. Complete rolling chassis was done prior. Only thing they did was body and paint along with assy. The chassis is a Contemporary as is Body. They also used it at B-J Auction as a display car.

They never touched engine etc

Prior to exhaust the vacuum was way down and forget the actual gain at idle but think it was around 7" of vacuum with just the exhaust mod. They were that restrictive, sounds like they tried to take credit for exhaust too.

http://www.kitcarmag.com/featuredvehicles/98898_shelby_mustang_cobra_replica/viewall.html

 

[Ben Iv]

Here are a few I did for the garage at home first my bench grinder stand 1 1/4" plate for the base with a 3x1/4 tube. Then my vise stand which has a 2" plate with another 3x1/4 tube. My table is just tube and channel with a 1/4" plate on top would have rather had somthing thicker but it was free. my welder cart is made of 3/4 by 16ga square tube with wheels from a dead lincoln plaslma cutter for a more store bought look...lol zero dollars spent except on paint and a pice of chain to hold my bottle. which was also free, being the foreman at steel fabrication shop has its perks.

 

[Ben Iv]

It was a little slow at the shop so I had the time to make a few improvements. a set of fork extensions for one of the forklifts. Then I built a new set of rollers for our bandsaw. I made the extensions from a pice of 4x6x3/8 tube split it down the middle and taperd the ends, cut it with a track torch nice clean straight cuts. To try and keep the seprate halves from bowing badly I made multiple cuts leaving tabs between on both sides then after it cooled i came back with a hand torch and cut the tabs. You can actually watch the cuts expand and then go back as it cools. I didnt get any progress pics of the rollers but they are made of 3x5 channel and square and rect tubing. the shop is way too clean in that pic so the last one is what it is suposed to look like...lol

 

[AL-DIABLO]

My pops wanted a hook to drag along a lake bed to see what he could find. I whipped this up for him-

 

[AL-DIABLO]

Here is a set of stainless z-bars. I coped the ends instead of the normal 90 degree miters. Capped the ends and sanded smooth. I hate seeing those open tube handlebars-

 

[bryna]

Not the best pic... I welded up a new welding table. Got a 4 X 8 X 3/8 sheet of steel from a local scrap yard, cut it to size, welded two sheets together for the top and bought square tubing for legs. I also put two receiver ends on the table which I use for temporary attachment of a standard and pipe vise.

 

[Capstone]

Here is a set of stainless z-bars. I coped the ends instead of the normal 90 degree miters. Capped the ends and sanded smooth. I hate seeing those open tube handlebars-

These are just a whole other level of welding that most can barely hope to achieve. Nevermind the fact that its TIG, but just figuring out the angles and cuts on this makes my head swim. Thanks for sharing.

 

[srmofo]

These are just a whole other level of welding that most can barely hope to achieve. Nevermind the fact that its TIG, but just figuring out the angles and cuts on this makes my head swim. Thanks for sharing.

Someone please forgive my if Im wrong, but a tube notcher does a hell of a job for coping objects to round objects.

 

[AL-DIABLO]

someone please forgive my if im wrong, but a tube notcher does a hell of a job for coping objects to round objects.

yeah, a tube notcher is one of my favorite tools. I guess i just like using the term "coped" joint.

 

[zmotorsports]

Weekends project was a swing away spare tire carrier for my son's new to him Jeep LJ. We added one of our custom tire carriers to the Expedition One rear bumper. I didn't see much sense in fabricating one of our bumpers as the Ex. One was a well built piece so we just added to it.

Mike.

Plates cut and drilled from 3/16" P&O for the spare tire mount and the third brake light mount.

Brackets prepped and ready to be tacked in place for test fit.

Mocked up after spindle has been welded into the bumper for the pivot point.

Here are a few closeups of the welds. I have also posted these in the "MIG Welding Technique" thread.

On the bench completing the welding.

Final welding completed and mocked into place one last time. Now ready to blow apart and send off to powder coater.

Tramp stamp fabricated and mocked into position. This will hide the unsightly rear HVAC ventilation exhaust. It will be spaced out approx. 3/4" with machined spacers and will be powder coated black to match all of the other components that we fabricated.

 

[theoldwizard1]

What is the wall thickness on that tubing ? Must weigh a ton !

 

[btamkel]

looks good nice job!

 

[e-tek]

Not bad z.....but you could have added a little more heat.

 

[zmotorsports]

What is the wall thickness on that tubing ? Must weigh a ton !

Plate was .187" and tube wall was .120". Didn't weigh as much as you would think. I didn't weigh it but easily lift it on/off and it swings very smoothly. I would bet it weighs less than 50 pounds.

looks good nice job!

Thank you.

 

[NASTYZEN]

Nice ZM. Your welding keeps improving all the time. Your heat seems just right to me.
You must be getting pointers from Paul. ; - )

 

[e-tek]

Nice ZM. Your welding keeps improving all the time. Your heat seems just right to me.
You must be getting pointers from Paul. ; - )

Of course I was kidding!! I'm no one to be giving you guys welding advice!!!

 

[gbsmithy08]

Here is a work project I just finished.
It is out of SS and copper tubing using silicon bronze TIG welding. Used my PLASMA cutter for the letters then heat colored it.

 

[IONH]

Here is a work project I just finished.
It is out of SS and copper tubing using silicon bronze TIG welding. Used my PLASMA cutter for the letters then heat colored it.

Looks good!

Was the Plasma work done by hand?

 

[NUTTSGT]

They're elsewhere on here but I'll add these.

 

[zmotorsports]

Nice ZM. Your welding keeps improving all the time. Your heat seems just right to me.
You must be getting pointers from Paul. ; - )

Thanks. I don't think I am in the same league as Paul (ZTFab) but thanks for the compliments. I will admit I have admired his work for several years now and seem to always have images of his work in my head and try to use that as a target or goal. He truly is an artist with a welder and seems to be very willing to give advice. The biggest issue I see is those he tries to help either don't take his advice or think there is some other tricks that he is not sharing. I have been welding for many years and feel very comfortable behind a welding helmet but over the past several years as my motorsports business has taken off it seems more and more clients are wanting that distinct/defined ripple or stack of dimes look. I have been trying to develope that technique and actually really like the finished result when done properly.

No tricks just lots and lots of practice and dedication. I hopefully will be that good some day but until then I had better get back to practicing.

Mike.

 

[StumpXJ]

Built another winch bumper for a buddy of mine.

 

[zmotorsports]

Looks good as usual Stump. When are you going to go into mass production of those things?

Mike.

 

[TimeWarpF100]

So a neighbor asks "Can you weld Aluminum?" I can, what do you need welded?

Neighbor: A body panel for my dune buggy.
Me: I normally do not like to do projects now because I have so much of my own to do but . . .

Neighbor, Ok.. How much would you charge to do a few welds?

Me: Really depends on how much welding there is to do but I need *** amt to cover my expenses of running the welder and *** for my time.

I was probably to expensive at half of what I should have said. Did not hear anything for a week then a couple days ago he stops by with this mess he had someone do it for CHEAPER! LOFLOL Now wonders why it will cost more to do than before? I think I will just tell him to take it elsewhere. What would everyone else here do in this case? I was trying to do a favor but at this point pretty much lost interest especially as he was supposed to show up 2x to help and never showed. I do not want my name anywhere near this mess.
The $$ just went way up . . . Does not matter how I try to repair it will never match the other side without starting over. Note how a piece was screwed on as it was cut too short, side edge was also cobbled on as cut too short etc