Fabrication 101

Discussion in 'The Garage' started by xcflyn, Feb 4, 2013.

  1. phreakingeek

    phreakingeek rookie adventurer

    Joined:
    Sep 17, 2010
    Oddometer:
    615
    Location:
    VA
    You guys are doing some very cool stuff! Thanks for posting the step-by-step pics.

    btw, did anyone identify the vent looking part?
    #41
  2. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    769
    Location:
    Chantilly VA
    Tent stove out of scrap laying around the shop, has an adjustable bypass damper built in.
    [​IMG]
    [​IMG]
    [​IMG]

    Cable operated decomp for a cr500, really needs a proper bracket and attachment method.
    [​IMG]
    [​IMG]
    [​IMG]
    #42
  3. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    769
    Location:
    Chantilly VA
    Machining a swingarm for a engine swap
    [​IMG]

    [​IMG]

    Tool to bore and face the swingarm
    [​IMG]
    #43
  4. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,155
    Location:
    Rocky Mountains
    That d-comp is a work of art ! The bracket should be the easy part.
    I looked at that stove and thought " man you could heat a house with that", I bet you get a tent mighty cozy :wink:
    Thanks for the post !
    #44
  5. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    769
    Location:
    Chantilly VA
    went to start on a set of cr500 swingarm extensions this morning, started to move my bandsaw and promptly broke off the lower guide:
    [​IMG]

    briefly contemplated buying a much larger saw, but decided against that. i figured i could machine up a new guide, but how to cut the stock with out a saw..
    [​IMG]

    Being lazy I just cleaned up what was left of the guide in the mill
    [​IMG]

    stock cut to length, top of the guide machined, and the other half of the broken guide
    [​IMG]

    new lower section being machined
    [​IMG]

    marked and center drilled
    [​IMG]

    drilled
    [​IMG]

    tapped, and bolted together
    [​IMG]
    #45
  6. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    Must.....resist.....this......thread.......



    You guys are killing me!



    I'm in the grips of lathe / mill envy. :clap


    Nice work by all. Thanks much for sharing.
    #46
  7. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    769
    Location:
    Chantilly VA
    Hgr has a large selection of mills... Just saying :evil
    #47
  8. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,155
    Location:
    Rocky Mountains
    But the question is- how did you break that guide off when moving it ? I worked in a shop years ago with a similar type saw that had a long adjustable guide on the opposite side, a piece of material landed on the saw while cutting and the guide broke but and the blade didnt, some of that cast is not very good, I recall welding it was a treat, like welding with the gas off. Nice work ! I think I see a new saw in your future ?
    #48
  9. jar944

    jar944 Been here awhile

    Joined:
    Aug 2, 2010
    Oddometer:
    769
    Location:
    Chantilly VA
    Pure stupidity on my part, I had a small table for vertical cutting on and the saw was resting on it in the down position. The table bolts to the lower guide. I put some downward pressure when I moved it and it snapped. The guide is cast Al, and judging how it was breaking when milling not a very good casting.

    Ive been wanting a larger 7x12 saw since I bought this 4x6 10 years ago..
    #49
  10. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,155
    Location:
    Rocky Mountains
    Heres a simple one.

    [​IMG]

    This is a top retainer I made for my tank pump, the weld is the result of me screwing it up, forgot to set the 0,0 and cut into the lead-in from the last cut on the sheet. Then the center drop flipped after being cut and caught the nozzle which is why the hole is not perfect. The only thing perfect was the example of how the easiest part can turn out the worst when your head isnt in the game. End result - it worked and It was for me so I dont have to recut it.
    #50
  11. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap

    Kirkster, I can meet you there too!!! If you've never been it's pretty fun to walk around the place they have a TON of stuff
    #51
  12. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    Finished welding the subframe tank

    [​IMG]
    #52
  13. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    What/where is hgr? I've got my eyes on a fully tooled Clausing here locally, but I need to sell a LOT of panniers first. Heheheh...

    Sailah, your welds are lookin' mighty fine! Keep up the good work! :freaky
    #53
  14. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    Hgr industrial surplus in euclid oh. Check it out.

    I only showed the good side haha. I need some more practice. I find the heftier metal easier to weld
    #54
  15. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,155
    Location:
    Rocky Mountains
    I think those welds look great !
    #55
  16. sailah

    sailah Lampin' it

    Joined:
    Aug 12, 2005
    Oddometer:
    5,864
    Location:
    Turning expensive metal into scrap
    Even a blind pig finds a truffle every now and then.lol

    Outside 90 degree corners are still a struggle for me. Flat welds and valley welds are easiest for me. That plate flange welded beautifully with nice fat beads. The thinner aluminum is always a delicate dance I find.

    I also have no good place to sit down and weld. Everything is welded standing up with out good elbow support. That makes a huge difference in consistency I think
    #56
  17. LocuL

    LocuL Gnarly Infantry

    Joined:
    Dec 5, 2006
    Oddometer:
    1,405
    Location:
    Denmark - Jutland
    Sailah...those skills are mad. Keep it up

    :freaky
    #57
  18. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,155
    Location:
    Rocky Mountains
    New project. Starting with a 1/2" plate here
    [​IMG]

    Turn it into a couple plates like this
    [​IMG]

    Then start welding the frames.
    [​IMG]

    I have very little idea what the end use is, but I know everything on this job is heavy. We will see what tomorrow brings
    #58
  19. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    Nice work, Dan-o!

    Thanks for posting up your work. :clap
    #59
  20. xcflyn

    xcflyn Long timer

    Joined:
    Mar 20, 2010
    Oddometer:
    1,155
    Location:
    Rocky Mountains
    More on the project or as some may view it: a moron on the project :D

    This is called a pallet when complete. I holds a #3000 lb eye on the sky microwave something or another that looks at ..... well I dont know what it really looks at but what ever it is and doing- this is a lot of material for something that only weighs 3k,less then 5' tall and rated for 152mph vertical wind.
    These are the lifting points that will get attached maybe tomorrow.

    [​IMG]

    Some tiny threaded rod to be cut 1.3/8 -6 B7 (4140)

    [​IMG]

    Tig welded into 3/4" support - top welds not too pretty, I am a little out of practice and the course thread liked to mess with me a little as you walked around them, the top weld is technically a water seal the original plan did not call for it, it went back to the engineer for approval prior. The bottom is plug welded where the rod is chamfered and set in .300" , it's a big plug weld
    [​IMG]

    End of the day test to make sure the mount plate fits, dropped on but I do admit I had to adjust two of the 8 just to get them centered perfect, I fear after all this finish welding if they are not perfect now it could be a headache later.
    [​IMG]

    Its nice to a have a job where I can work for days on pieces then like a puzzle start building, just cool shit (IMO)
    #60