Show us your welding projects

[Farmall450]

Larry a friend of mine was over at my house trying out my oldish (2002) Miller synrowave 250dx. He actually came over to weld something. Though he realized that he needed more then one piece of rod. So he joined two pieces together. Some people just like to show off.

It's not too difficult, my shop teacher in high school was big on that.

 

[kkroger]

They are supposed to pick it up with a Semi on Tuesday... Have to coordinate a Boom Truck and some other support at the jobsite... It curled up like a Banana for a while, but we got her all calmed down...

 

[1953mercury]

Looks great, and an interesting structural design. Did you control the bending by the order that you welded the gussets in? Mike

 

[kkroger]

Not really. It looks like some kind of heater vent or something. However, congrats on keeping it straight after laying down all that weld.

Now, please tell us exactly what it is?

It is shaped like a kite...

Never in my life have I seen a "Heater Vent" made from 5/8 plate with 3/8 thick KITE shaped formers... you seriously can't see that it is shaped like a kite in cross section? in the earlier pics there are only 3 of the 4 sides shown tacked in place, each KITE shaped former is full welded in place, and the outer plates are full welded inside EXCEPT the last plate the formers are 8" apart, there just ain't no way to get a little guy in there to weld the last plate on...
the wider plates are 7" the narrower are 4 5/16, the wider plates had to be beveled with a track torch on one edge. then all the seams had to be stitch welded (Skip Welded) in 4" segments it still curved up we shrunk it with a rosebud in a couple spots, we cut it and laid it out in a couple spots, all of the seams had to be filled and high so they could be ground back down and profiled, at one point there were 3 of us skip welding 3 different seams trying to avoid being right next to each other, then letting it cool completely then stitching it some more. the Baseplate is 3/4" Plate cut on the plasma table to shape. it is a vertical structural post that separates the glazing on the front of a house. since there is no real support on that wall except the side posts and this post, we were the second attempt at this another shop tried it and couldn't get it straight. I just finished welding the last seam and filling in gaps and grinding the last seam this morning. Then sprayed it with Red oxide primer

 

[ndr1968]

It is shaped like a kite...

Never in my life have I seen a "Heater Vent" made from 5/8 plate with 3/8 thick KITE shaped formers... you seriously can't see that it is shaped like a kite in cross section? in the earlier pics there are only 3 of the 4 sides shown tacked in place, each KITE shaped former is full welded in place, and the outer plates are full welded inside EXCEPT the last plate the formers are 8" apart, there just ain't no way to get a little guy in there to weld the last plate on...
the wider plates are 7" the narrower are 4 5/16, the wider plates had to be beveled with a track torch on one edge. then all the seams had to be stitch welded (Skip Welded) in 4" segments it still curved up we shrunk it with a rosebud in a couple spots, we cut it and laid it out in a couple spots, all of the seams had to be filled and high so they could be ground back down and profiled, at one point there were 3 of us skip welding 3 different seams trying to avoid being right next to each other, then letting it cool completely then stitching it some more. the Baseplate is 3/4" Plate cut on the plasma table to shape. it is a vertical structural post that separates the glazing on the front of a house. since there is no real support on that wall except the side posts and this post, we were the second attempt at this another shop tried it and couldn't get it straight. I just finished welding the last seam and filling in gaps and grinding the last seam this morning. Then sprayed it with Red oxide primer

Just goes to show, if some architect can dream it up, somewhere there are craftsmen who can make it happen.

As far as naming stuff goes, though "kite" seems to describe a cross sectional appearance, it would seem that "spar" or "mast" would be more descriptive of function...just say'n.

 

[kkroger]

Just goes to show, if some architect can dream it up, somewhere there are craftsmen who can make it happen.

As far as naming stuff goes, though "kite" seems to describe a cross sectional appearance, it would seem that "spar" or "mast" would be more descriptive of function...just say'n.

I did call it a BEAM... Guess you missed that right after I described the SHAPE of said BEAM with Kite SECTION...

 

[hsvtoolfool]

...you seriously can't see that it is shaped like a kite in cross section?

No one can. Your camera angles do no show the
cross section. The first photo looks like two 90-deg
edge-welded plates with a separate third plate
sitting behind them. The second photo looks like
a square tube.

 

[Cue]

No one can. Your camera angles do no show the
cross section. The first photo looks like two 90-deg
edge-welded plates with a separate third plate
sitting behind them. The second photo looks like
a square tube.

Not sure what pictures you were looking at but I can plainly see the Kite shape in both pictures, and he said it was a kite shaped beam.

 

[toolferone]

Hey Toolferone: From the height of that stand you must be about 8' tall.

Well turns out you were right. Here it is done and the center of the wheel is 47" tall. I will try and use it for a bit and see how awkward it feels.

 

[twarren]

I just finished a grinder stand for two bench grinders. I used a truck brake drum which is heavy enough to stay put but light enough to move out of the way when not needed.
Twarren.....

 

[Redlunn]

Not sure what pictures you were looking at but I can plainly see the Kite shape in both pictures, and he said it was a kite shaped beam.

I'm with Cue, I'd never heard of a kite shaped beam before the original post but the info and pics provided by kkroger made it clear what he was making.

 

[royce]

I just finished a grinder stand for two bench grinders. I used a truck brake drum which is heavy enough to stay put but light enough to move out of the way when not needed.
Twarren.....

Clean, sharp work, nicely done.
Royce

 

[RivennHewn]

KKroger,
Looks great.
Did you have any special inspections/ UT/ Visual on that?

 

[royce]

They are supposed to pick it up with a Semi on Tuesday... Have to coordinate a Boom Truck and some other support at the jobsite... It curled up like a Banana for a while, but we got her all calmed down...

That is no small feat keeping something that long with continuos longitudinal welds on 4 sides straight.
Well done.
Out of curiosity,how much deflection did you end up with?
Excellent work.
Royce

 

[kkroger]

That is no small feat keeping something that long with continuos longitudinal welds on 4 sides straight.
Well done.
Out of curiosity,how much deflection did you end up with?
Excellent work.
Royce

Max deviation is 1/4" over 30'... not only continuous but DEEP and WIDE... and piled up beads... and of course starting with flatbar provided by the contractor and picking the straightest pieces which had at least that much deviation...

 

[ndr1968]

Not sure what pictures you were looking at but I can plainly see the Kite shape in both pictures, and he said it was a kite shaped beam.

Doh! Finally, I can see it! Weird. Sort of like when you look at a moon photo upside down, all the craters become mountains. I don't know what but something was "hiding" that shape in there! I think it's because all the sections except the very end one are hidden in shadow and also, the one side being open destroys the symmetry. Whatever, one masterful piece of welding to be sure!

 

[toolferone]

I just finished a grinder stand for two bench grinders. I used a truck brake drum which is heavy enough to stay put but light enough to move out of the way when not needed.
Twarren.....

Very nice! I've been looking for the truck drums, just no luck yet. Mine works, yours looks WAY better then mine!

 

[hsvtoolfool]

Not sure what pictures you were looking at but I can plainly see the Kite shape in both pictures, and he said it was a kite shaped beam.

Only if you viewed his earlier photo. I follow this thread
closely, but I also overlooked the earlier photo 2 pages
back. I checked the thread that day before kkroger's first
post. Unfortunately, there were about 10 posts that day
after I checked (which is abnormally high traffic). These
posts forced the more revealing photo you referenced
back a full page. When I checked the thread the next
day, I saw the gorgeous A-frame house and instantly
understood why the beam would have a "kite shaped"
cross-section. Naturally, it didn't occur to me to go
hunting a page back to view a photo I didn't know
existed. The main thing I noticed yesterday was the
rather rude response from kkroger to ngr1968, so I
tried to explain why the questions were sincere and
understandable .

 

[ndr1968]

See how it is shaped like a kite?

At the risk of having that old shoe thrown at me, I’m dragging this sock monkey out and biting it and shaking it one more time (Picture a dog playing with a toy -BITE that MONKEY!).

The end section does look like a kite but the top piece in that position and viewed in that perspective creates the illusion of the apex of the shapes being shifted to the right (or “down” in the photo). Thus, the symmetry is destroyed and they look more like irregular rhombuses.

Lightening the shadows helps one to mentally “flip” the tops back to where they should be.

 

[jimgood]

At the risk of having that old shoe thrown at me, I’m dragging this sock monkey out and biting it and shaking it one more time (Picture a dog playing with a toy -BITE that MONKEY!).

The end section does look like a kite but the top piece in that position and viewed in that perspective creates the illusion of the apex of the shapes being shifted to the right (or “down” in the photo). Thus, the symmetry is destroyed and they look more like irregular rhombuses.

Lightening the shadows helps one to mentally “flip” the tops back to where they should be.

 

[spent21]

agreed. let it die.

 

[RXtacy]

Finished my driveway gate.

A video of it in action.

 

[zmotorsports]

Finished my driveway gate.

A video of it in action.

Gate turned out awesome.

Mike.

 

[Tunafromlaguna]

Gate turned out awesome.



Mike.

Pretty cool. I put portholes on my gate for my hounds. .


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[Tunafromlaguna]

Pretty cool. I put portholes on my gate for my hounds. .


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[RXtacy]

Gate turned out awesome.

Mike.

Thanks Mike.

 

[bbcc]

Found myself needing a light/medium duty press for dimple dies/ u joints/ misc bushings and bearings. I really enjoy arbor presses for the feedback they provide along with the unlimited length of material. I have limited space so a traditional bridge style press would need to be against a wall severely limiting the length of work piece I can handle.

This design is neat because it can convert from hydraulic to manual for those times you want finer control (ie. pressing in small pins) by pulling the three pins and spinning the load arm around. I can't take credit for the idea though; it's based off of an old popular mechanics picture I stumbled upon while brainstorming the project.

Not the most brilliant MIG welds, certainly pushing the capacity of my little MigPac10.

 

[jhn9840]

Mig welds look good to me

jhn9840
John

 

[sberry]

I agree the welding is fine and wouldn't have a problem paying a guy for it.

 

[phred]

Nice work.


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[Mario428]

Found myself needing a light/medium duty press for dimple dies/ u joints/ misc bushings and bearings. I really enjoy arbor presses for the feedback they provide along with the unlimited length of material. I have limited space so a traditional bridge style press would need to be against a wall severely limiting the length of work piece I can handle.

This design is neat because it can convert from hydraulic to manual for those times you want finer control (ie. pressing in small pins). I can't take credit for the idea though; it's based off of an old popular mechanics picture I stumbled upon while brainstorming the project.

Not the most brilliant MIG welds, certainly pushing the capacity of my little MigPac10.

Nice work, like the concept

 

[ndr1968]

Found myself needing a light/medium duty press for dimple dies/ u joints/ misc bushings and bearings. I really enjoy arbor presses for the feedback they provide along with the unlimited length of material. I have limited space so a traditional bridge style press would need to be against a wall severely limiting the length of work piece I can handle.

This design is neat because it can convert from hydraulic to manual for those times you want finer control (ie. pressing in small pins) by pulling the three pins and spinning the load arm around. I can't take credit for the idea though; it's based off of an old popular mechanics picture I stumbled upon while brainstorming the project.

Not the most brilliant MIG welds, certainly pushing the capacity of my little MigPac10.

Could you show photos of this in manual mode, please? Also stock dimensions? Thanks

 

[bbcc]

Could you show photos of this in manual mode, please? Also stock dimensions? Thanks

Hey ndr,

I won't be able to grab a pic for a few days. However, here's the original article which shows the operation in hyd/manual. I changed a few things up in the design....after some trial by fire found the deficiencies. I managed to pretzel the load arm after the first dimple die in 1/8" steel. Rebuilt it and added some more material in the high moment areas and it's been great since.

Material is: C3x5.0 channel, 2" x 1/4" sq. tubing, the ram slide is 2" x .188", the ram and pivot are 1.5 x .25".

Only trickery was on the ram slide. Since 1.5 x .25 will not slide into 2 x .25 without considerable massaging (weld seam on the ID) I decided to use 2x.188 wall instead to create some clearance. I tig'd some beads with er80 filler (harder than the A500 tubing) to build up a lip on either end of the ram slide. With a carbide followed by a ******* file I worked the lip into a nice flat bearing surfaces. Net result is a smooth running and bind free movement of the ram in the ram slide.

Hope that wasn't too long winded

 

[ilovevocs]

Nice work and thanks for sharing the design. I'm thinking this could replace my 20 ton for most if not all of my applications.

Running out of floor space in my shop.


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[50cal]

Very nice Thank You

 

[1969]

Interesting ^^^

 

[Hybridss]

Found myself needing a light/medium duty press for dimple dies/ u joints/ misc bushings and bearings. I really enjoy arbor presses for the feedback they provide along with the unlimited length of material. I have limited space so a traditional bridge style press would need to be against a wall severely limiting the length of work piece I can handle.

This design is neat because it can convert from hydraulic to manual for those times you want finer control (ie. pressing in small pins) by pulling the three pins and spinning the load arm around. I can't take credit for the idea though; it's based off of an old popular mechanics picture I stumbled upon while brainstorming the project.

Not the most brilliant MIG welds, certainly pushing the capacity of my little MigPac10.

Love it! Thanks for sharing.


Here is my workbecnh I have been working one. This is like my third welding project of any size since I began welding a couple years ago.

 

[bbcc]

Oh nice! Lookin good Hybrid!

I'm feelin the mini fridge haha. And, maybe it's the mood I'm in, but I thought that little round dude chilling beside the fridge was a bottle.....but upon closer inspection it looks like an air quick connect?

 

[ilovevocs]

Nice looking setup you have their.

I'm feeling more and more like im ready to loose my industrial bolt bins and small parts storage and go to the plastic totes.

I have a few and find them so much more convenient for small parts storage.

I have dedicated boxes for particular types of work and it's simple to take them to the work even if I'm working away from the shop.


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[node105]

Rafter jig - where does the time go? ( sourcing and replacing a Fine voltage switch on the Mig welder, welding in the second mezzanine, installing flooring on the 2 mezzanines, shimming the column heights to the mm... and coping with the bouts of rain stopping play, interspersed with warmish weather - 42degC today and yesterday)

Got bracing in to the walls, and a small bashing table made in the last few weeks

Got the material for the rafters (RHS 100x50x2), and using the end wall as a jig base.
Rafters sitting at 30.0 degrees, restrained by the columns, which gives a the final installed width of course.

The original plan was to weld endplates to both rafters of each pair, 5mm at the rafter to column end, and 8mm at the apex, then lift and bolt together (M16); have the mezzanines to stand on of course.

Then I though why not just weld the pair together, and changed the apex plate to 16mm. There will be a gantry attached to the apex plates, across the middle open bay only, so these are predrilled (for M16 x50 bolts). Massaged the hole locations to give 2 bolt diameters from each end of the apex plate, and adequate clearance to slip the bolts in once the rafters are welded; trying to maximise every 10mm of headroom on the mezzanine.