Show us your welding projects

[little d]

Boost,
I second a thread on the bender. Ive seen plans on them, just never seen anyone go step by step building one.

 

[Boost Creep]

Boost,
I second a thread on the bender. Ive seen plans on them, just never seen anyone go step by step building one.

no problem. here ya go.

http://www.garagejournal.com/forum/showthread.php?t=293232

 

[brawls43]

I built one of the Frank Takac's benders and posted some pics of the build back when we were building it in order to build our race car roll cage.

Start: http://teambearpatrol.blogspot.com/2010/02/starting-bender.html
Welding: http://teambearpatrol.blogspot.com/2010/02/more-work-on-bender-kills-chopsaw.html
Bending: http://teambearpatrol.blogspot.com/2010/03/build-day-36-more-pics.html

Frank has a nice set of plans.

 

[little d]

Boost,
thank you, I thought you built the bender itself and not just the stand but again, thanks for the post.

Brawles,
thanks,
when I get the time I'll spend some time on your blog and check it out,
D

 

[F-117HWK]

I'm around the Roanoke area :flipoff2:

Ah good deal, I actually went to school at Radford and had a class up in Roanoke as well.

 

[Todd.Brock]

I'm a Roanoke College grad. I had a buddy with a a farm in Bedford and roommate from New Castle. Live in old SW for a lot of years.

 

[bmxdad]

How do these look ... also, what is the paint looking residue? Using solid wire with 75/25 gas.

 

[amusick10]

How do these look ... also, what is the paint looking residue? Using solid wire with 75/25 gas.

Just pulled the impurities out, no harm no foul.

I think some have said silicon or something too but I'm not sure.

Sent from my HTC One_M8 using Tapatalk

 

[welder4956]

How do these look ... also, what is the paint looking residue? Using solid wire with 75/25 gas.

Those are silica deposits. The weld wire uses silicon for deoxidation, when it combines with oxygen in the puddle it produces silica. You should be able to break them off with a chipping hammer or a couple of light taps with a cold chisel.

 

[doojus]

Finished up the squat rack that I had to drill a million holes on, pretty glad to be done with it finally.

 

[bmxdad]

How wide, from the inside, is it? Looks a little narrow, but probably the angle.

Are the plates on the bottom permanent ... one looks backward? Looks like a nice project, how many linear feet of the big tubing is there?

 

[doojus]

How wide, from the inside, is it? Looks a little narrow, but probably the angle.

Are the plates on the bottom permanent ... one looks backward? Looks like a nice project, how many linear feet of the big tubing is there?

It's 43" across and 30" deep, it's the exact dimensions as racks you would see in gyms.

About the feet... They are permanent. I drilled the holes on one of the verticals wrong apparently, so the cups would only fit smoothly with it turned around. I told the guy I'm making it for that I could plasma gouge the welds off and and possibly damage the tube or plate to get it off and turn it around, he didn't seem to care too much about it being backward. One of those live and learn deals, this was my first major fabrication project so I made quite a few mistakes.


I think we bought 48' of 3x2" 11 gauge and had a little left over.

 

[SLYDIT]

heres my driveway gates. 2" squre tubing with 1" cross bars. grooved shadow clad plywood. the ply will be stained a very dark grey/brown colour. the bolts are 304 stainless coach bolts which should really pop visually frame wil be black powder coat.

 

[polydan]

now ever evolving project teaching me patience and getting me more comfortable welding.

Holy **** man! "more comfortable welding"!!! I follow you here and on FB...you my friend are to modest!!!

 

[E12-535iTurbo]

I like your gate design, so is it completed now? If so, please post another photo or two. What kind of bender are you using? How about the hinge system?

http://www.garagejournal.com/forum/showthread.php?p=4913898#post4913898

There are a lot more pictures there. But to answer your questions:
1. I've made a bending jig from particle board and hand bend both curved profiles over that jig.
2. The hinges are premade weld-on types which I purchased. They were about 6 euro's a piece and are well capable of the load. There is a picture of them in the topic link I posted.

 

[1953mercury]

Broke the front sway bar on the T-Bird over a year ago. Only one source for this and with shipping was closing in on $400. Most sway bars run less than half that amount. So after my usual procrastination I decided to try welding it. Now, I realize the safety Nazi's will frown on this approach, but it seemed like the thing to do, so I did it. Took some measurements, vee'd it out wide from two sides, preheated, and welded it up with a high nickle rod in multiple passes with a lot of furious peening after each pass. Had a pile of lime set up and once I had it built up where I wanted it, I set it in the lime and piled some more on top. Let it set overnight and cleaned it up with a grinder the next day. Painted it and installed it. Have a few hundred miles of spirited driving on it now, and no signs of distress. Mike

 

[56rpm]

I needed to make an engine crossmember for my 69 Mustang in order to lower the engine. The stock crossmember wouldn't allow any drop of the engine. So I drew up some plans, bent some tube, notched the ends and welded it up.








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The crossmember is welded upside down on the welding fixture.

 

[BlueBomber]

Nice work, gents!

 

[zmotorsports]

I needed to make an engine crossmember for my 69 Mustang in order to lower the engine. The stock crossmember wouldn't allow any drop of the engine. So I drew up some plans, bent some tube, notched the ends and welded it up.








]



The crossmember is welded upside down on the welding fixture.

Nice work. Good planning and execution. Turned out great.

Mike.

 

[MillerMav]

I am definitely stealing that tube cutting jig idea. That's slick!

 

[bagged89s10]

I needed to make an engine crossmember for my 69 Mustang in order to lower the engine. The stock crossmember wouldn't allow any drop of the engine. So I drew up some plans, bent some tube, notched the ends and welded it up.

















]







The crossmember is welded upside down on the welding fixture.

Nice work on that crossmember. Sure beats the way I built a similar bolt on crossmember for the rear shocks on my truck a long time ago. I remember welding it on the floor and angle grinding the notches for tubing.

Was that notching done on a mill? Can't tell on the pic.

Good work!

 

[zkling]

I needed to make an engine crossmember for my 69 Mustang in order to lower the engine. The stock crossmember wouldn't allow any drop of the engine. So I drew up some plans, bent some tube, notched the ends and welded it up.

Great job, a good welded tubing joint always starts with a close fitting notch.

 

[Beemer533]

I'm around the Roanoke area :flipoff2:

That came out really nice, I like it... Other than the fact that now you can barely see that nice bolt face sticker of course...

 

[Ckengine]

New bench

 

[bggrnchvy]

Finished up the squat rack that I had to drill a million holes on, pretty glad to be done with it finally.

A couple years back I built an infinity rig for a relative starting a crossfit gym.

Even with a mag drill, I never wanted to drill another hole again.

 

[kazlx]

 

[doojus]

A couple years back I built an infinity rig for a relative starting a crossfit gym.

Even with a mag drill, I never wanted to drill another hole again.

I'm cringing just thinking about drilling that many holes, holy ****.

There's a place here that does laser cutting, I'd probably just outsource if I had to do it again.

 

[doojus]

Family has a horse business, I made some aluminum jumps for them. The old wood jumps are smoked after about 2 years and they're also too heavy for little people to move easily. I can pick these up with one hand, but they're strong enough that I could sit on the suspended jump

 

[Robert Hall]

I had a client ask for a gun display case for a shotgun that her dad found in 1977 while our hunting.

The shotgun is circa 1900 or so I'm told.

It's been displayed in a semi exploded fashion and held in place by 316 stainless steel fabricated and each standoff is held by a #10 stainless screw.

 

[bmxdad]

Did you make the feet? Those are nice ... simple design, but a nice touch.

 

[Lu-Max]

Thought ya'll might find this interesting: Wrench Welder Guy

 

[trackwelder]

Thought ya'll might find this interesting: Wrench Welder Guy

That's incredible!!!

 

[doojus]

Made this little parts bin out of 1/16" 6061 for my old man for father's day. The autogenous weld on the front didn't come out quite as good as I wanted but ah well.

 

[56rpm]

Was that notching done on a mill? Can't tell on the pic.

Good work!

Thanks guys for the kind words, you've really made my day! Yes, the notching was done on a mill. That idea was stolen from Kris at 44 Bikes Frame Shop who is an outstanding fab guy here on GJ.

 

[kazlx]

Did you make the feet? Those are nice ... simple design, but a nice touch.

Yes, CNC plasma. The top was a plain round from Lowes. I beat it up with some chain and stained it. I machined up a collar that's underneath to mount the top as well. Everything besides the top was scrap I had laying around. Figured as long as I was testing cuts on the plasma, might as well make something for the wifey.

 

[56rpm]

Nice work. Good planning and execution. Turned out great.

Mike.

Coming from a man of your talents Mike, I hold your reply in high regard. Thank you sir.

Bob

 

[E12-535iTurbo]

Finished the gate:

View media item 51365
And some close up's of the installation (back, left and front, right):

View media item 51364View media item 51363
Some details of the hinges as requested:

View media item 51367View media item 51368
Building process:

View media item 50693
Building a jig to cold bend the profiles over:
View media item 50695View media item 50694View media item 50701View media item 50702
Rough layout and welding (everything is TIG welded):
View media item 50696View media item 50777View media item 50698View media item 50697

No crushed profiles because of added support tubes. And recessed mounting screws:
View media item 50779View media item 50780
TIG-welding seems to go well:
View media item 51225
The end result was sandblasted, thermal sprayed and powder coated for maximum corrosion resistance.

 

[danscobra6]

Very nice. I've always considered Tig welding an art, more then welding metal together. It appears you have mastered it.

 

[bmxdad]

Finished the gate:
Building a jig to cold bend the profiles over:

View media item 50701.

So did you physically bend this? How did you keep the tubing from buckling?

Awesome job by the way

 

[Vieux]

Several small projects.
The table in the garden.











Bracket











Trolley for welding