Rookie wanna-be weldor starting to make some cool things!

Discussion in 'The Garage' started by kirkster70, Oct 3, 2010.

  1. kirkster70

    kirkster70 moto junkie

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    Thanks, Jim!

    Looks like you are doing some nice modifications yourself! Once you put a bottle on that welder, you will be surprised what a difference it makes. The beads can be almost as pretty as TIG.

    Flux core definately is good to have as well. MIG and TIG aren't the greatest outside in a breeze that blows away the sheilding gas. That's when stick and flux core can't be beat. Plus, stick and flux core need less surface prep and will burn through rust.

    Nice work!

    - Kirk
    #21
  2. kirkster70

    kirkster70 moto junkie

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    I have two friends that both have quite the assortment of welders and shop tools. The each have a Millermatic 140 MIG, and they both say they use it more than anything in their arsenal. You can get a new one for around $800.

    The only reason I went for the 252 was because I had the cash from the bike, and I wanted to do aluminum. I've read that the 120V machines can run a spoolgun for aluminum, but a 240V machine will handle aluminum much better because it takes tremendous energy to break through the oxide layer on aluminum. The 30A spoolgun on the 252 has a 100% duty cycle @ 200A, which basically means you will get tired before it does.
    #22
  3. motoretro

    motoretro Been here awhile

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    Just a reminder.....either invest in a welding fumes respirator for under your hood or a Collector system if you're going to get serious about this. FWIW

    Motoretro
    #23
  4. larry0071

    larry0071 Been here awhile

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    I like the KLR panniers. Very nice work. Don't worry about the classes, the welder and time will learn you up right and proper. When I learned to weld about 6 or 7 years ago, I would weld flat plate in butt weld config and lap seam config and then put one piece of the two in a vice and blast it with a 3lb mini sledge hammer to see if the joint would bust apart of the material would bend outside of the weld. In the beginning there were pieces of mettle flying in all directions from what appeared to be "pretty" welds, after some time and reading online as well as a few union welder buddies stopping by to LOL at me.... the broken welds stopped.

    Now I can fix just about everything but a broken heart with my shop. It's a great feeling, isn't it? I have a 79 F-250 setting on air bags with a custom 4 link that I built. My welds help up to a 1050 HP engine while sled pulling for 3 years before the truck got retired. Half the truck was hand built in my garage. I was proud of my junk! Still am.
    #24
  5. Tasy's BIGJIM

    Tasy's BIGJIM CornerGrinner

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mso-pagination:widow-orphan; font-size:11.0pt; font-family:"Calibri","sans-serif"; mso-ascii-font-family:Calibri; mso-ascii-theme-font:minor-latin; mso-fareast-font-family:"Times New Roman"; mso-fareast-theme-font:minor-fareast; mso-hansi-font-family:Calibri; mso-hansi-theme-font:minor-latin; mso-bidi-font-family:"Times New Roman"; mso-bidi-theme-font:minor-bidi;} </style> <![endif]--><!--[if gte mso 9]><xml> <o:shapedefaults v:ext="edit" spidmax="1026"/> </xml><![endif]--><!--[if gte mso 9]><xml> <o:shapelayout v:ext="edit"> <o:idmap v:ext="edit" data="1"/> </o:shapelayout></xml><![endif]--> Make a Canvas Cover for over that welder. Place a foam Ear-Plug over the wire. Wire Roll side of the Feeder Tube. Stops dust and shit from getting into your gear and Weld. Resist Grinding Welds Flat. Do it again. :cry?

    Vertical Uppers- If you can turn it all over and Lay it flat great. If you can't? Practise on waste welding "Christmas Trees" that’s starting at the Bottom. Across, and up. Across and up. Across... so on. Wide at the base.
    and so on. Please don't be offended. You are doing a great job. :ear BIGJim.
    #25
  6. kirkster70

    kirkster70 moto junkie

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    Yes sir, already in planning stages. I have a nice 24" explosion proof fan left over from my painting days from a redneck spraybooth.

    It will be modified for an updraft smoke eater to exit out a garage window.
    #26
  7. kirkster70

    kirkster70 moto junkie

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    Thank you very much!

    I've done some destructive testing on some of my practice pieces. I even cut some welds in half to see how much penetration I was getting.

    Sounds like you are making some amazing things! 1050 HP? Yikes! I'd say you must have done some good welding on that one!
    #27
  8. kirkster70

    kirkster70 moto junkie

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    Thanks for the tips. No offense taken whatsoever. I'm always willing to hear from guys who have already been where I want to go.

    I have seen a product you can buy to put on the filler wire, but a foam ear plug is an even better idea! Plus, I have a cabinet full of them!

    I know that grinding a weld takes a lot of strength out of it. I ground down the welds on my pannier racks where the bags would be touching. The Gator rack welds were only ground down to shape the mounting tabs.

    I still have my textbook from the stick class I took, but the book covers all welding, so I still go back through it for the exercises and for proper techniques for vertical, horizontal, pushing, pulling, etc, and have been learning a lot.

    Please fell free to critique me at any time. It's the only way we get better!
    #28
  9. Maggot12

    Maggot12 U'mmmm yeaah!!

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    Thanks for that info... I think I will just get a machine, some scrap stuff, do some reading and research, and have at it. I have some friends that are back yd welders and a few professionals as well, that I can get advice from.

    I always wanted to try it but not enough to actually attempt to learn. My dad and uncles owned auto garages and dealerships while I was growing up and I'm 21 yr helicopter mechanic. So I do have some abilities to start with.

    Thanks for helping me turn the corner and twisting my rubber arm.:1drink

    Cheers,

    <input id="gwProxy" type="hidden"><!--Session data--><input onclick="jsCall();" id="jsProxy" type="hidden">
    #29
  10. kirkster70

    kirkster70 moto junkie

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    You know it! Post up your progress when you get going! You definately have the mechanical skills if you are a heli mechanic. Go for it!
    #30
  11. kirkster70

    kirkster70 moto junkie

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    Ok, more pics. I hope I'm not offending anyone. I just have pent up welding ideas that are just now seeing the light of day.

    Here is my very first aluminum project. I did it with the spoolgun on the MIG. 1/8" 3003 aluminum cube by 3" square. This sucker kicked my butt. It took a whole day to cut it out with my caveman tools (before the plasma)

    The grinder made me look like I knew what I was doing. The welds were ugly before!

    I did this to dial in the spoolgun and know what to expect. I had plenty of burn back on the tip and finally got the wire speed set for decent results. There is some porosity, but I think it's from where I didn't clean the aluminum as good as I should have. I do have a dedicated brush for aluminum, so I knew about that from studying my book. Sorry for the huge pic. My pc started to lock up when resizing, so I let it roll.

    [​IMG]
    #31
  12. kirkster70

    kirkster70 moto junkie

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    The cube was actually my very first project out of the chute. It gave me the confidence to tackle project #2. I think my table may have been #3. Here is #2...a freakin' huge bashplate.

    I bought some decent sized aluminum sheets from a friend at work, so this is the first time buying materials.

    I made a mock-up first with some thin cardboard and then went to it. I also cut this out with caveman tools, so it also kicked my rear end. One whole day with a jigsaw running metal blades. What a freakin' nightmare! That's when I knew a plasma cutter was in my future. I used stock mounting holes, and stock hardware. I notched the left for the doohicky adjustment, and notched the bottom for oil drain access. Lots of using a hand file for shaping.

    [​IMG]

    I cut ventilation holes with a 1 1/8" holesaw. I think that's what led to the early demise of my DeWalt's trigger. She got a little too hot. It's already been fixed with a new trigger fround on ebay.

    I wanted better protection for the water hoses, hence the huge size. It looked funky at first, but I like it now. I have ideas to make it better, but I have more ideas that I'm already working on, so the lowly bashplate will have to wait. At least it's better than the stock plastic p.o.s.

    I ground the outside edges on this too, but I have some heavy fillet welds on the inside corners.
    #32
  13. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    My .080 5052 aluminum and bag hardware should be here this week. I will spraybomb my rack tomorrow and let her dry. Speaking of the rack, my estimation of weight is way off. I'd be fired at the circus.

    [​IMG]

    Uh.......holy crap! It weighs in just under 17 lbs. Oh well. It is what it is. It's going on the bike. I knew it was overkill at the onset, but i just had to push ahead due to the KLR cheapness disease. I didn't want to actually go out and buy 1/2" square tube. Now I pay the price of making a heavy bike heavier. I'm good with that.
    #33
  14. WhatThaFrig

    WhatThaFrig Been here awhile

    Joined:
    Jul 3, 2010
    Oddometer:
    282
    Location:
    KnoxVegas, TN
    Very nice work! Color me jealous!
    #34
  15. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    While the paint is drying and I'm waiting on the big brown truck, I have another project waiting in the wings...

    A redneck bike lift!!!!

    I had an old LTD 440 project bike that I got for free that I traded for this wheelchair lift that the other guy got for free. It was meant to be.

    The lift is rated at 750 lbs. and is gear driven. I will gut some of the control boxes and then mount one box on the L and one box on the R. I will extend the base, extend the platform, make some mounting ears, and bolt it to the concrete garage wall and floor. I will figure out some kind of drop down or removeable leaves for lifting ATVs, mowers, etc. I will also make a wheel clamp for bikes. This will happen after the bags are completed, unless I'm still waiting for parts.

    [​IMG]



    I also have another project lurking in the building...and old, abandoned ATV that I was given that will become an offroad wagon for campfire wood gathering operations.

    So, see? It's a friggin' sickness. I go to bed, then wake up with more ideas. And somehow, they seem to work out. I had dreams for about 3 weeks telling me to get rid of the DL. No kidding. And yeah, I think I may be a bit psycho in case you couldn't already tell. :D
    #35
  16. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    Thanks!

    Hey - you're not the guy from Ghosthunters are you? He says your username all the time.
    #36
  17. B.Curvin

    B.Curvin Feral Chia tamer

    Joined:
    Feb 15, 2004
    Oddometer:
    2,774
    Location:
    Left of the dial. Canton, NC

    :clap :freaky

    I like your style.

    Seriously though. Great thread, and congrats on a couple of REALLY sweet welders.

    I was just about to buy a new Miller Syncroware 200 6 months

    ago but I blew most of that $$ on an old Rockwell Lathe. I bought Smiths welding torches with

    what was left but I'll snag that Miller eventually.

    Again, :clap :clap :clap :clap
    #37
  18. B.Curvin

    B.Curvin Feral Chia tamer

    Joined:
    Feb 15, 2004
    Oddometer:
    2,774
    Location:
    Left of the dial. Canton, NC

    I went through the exact same process. When I saw the all in price of

    a welding class I decided I'd buy a Tig unit and just dive in.

    As mentioned in my above post I wound up with these instead.

    Made in the US Smiths AW1A airline torches.

    [​IMG]

    A more clear picture.

    [​IMG]

    It actually worked out really well for my plans. When I started picking up

    welding books they all said a torch was the best way to learn. Plus I plan to

    do a lot of 4130 Chromoly and 4130 as it turns out was designed for

    light aircraft frames and was intended to be torch welded. It will weld anything short of

    Magnesium and I can cut with it. I learned to stick weld when I was 5 years old

    and did some production Mig welding but had only ever cut with a torch. Here's

    a few pics of my torch welding from earliest to most recent (a 6 month period).

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]





    Sometimes I get a little crazy.
    [​IMG]
    #38
  19. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    Thanks!

    That is a very nice torch setup. It looks like you are doing some nice work as well. I've always heard that if you can proficiently work a torch, then TIG is almost second nature. When you do get the welder, you'll already be ahead of the game.

    Nice!
    #39
  20. kirkster70

    kirkster70 moto junkie

    Joined:
    Aug 17, 2008
    Oddometer:
    1,905
    Location:
    Virginia
    I painted the rack today, so it's drying, and still no materials. I made good use of my time and tore into the lift.

    I gutted the nurse call, the alarm circuit, and everything that wasn't needed.

    The high and low limit switches and the EPO button are still operational. I bypassed the keyswitch, but it could still be functional with a new tumbler. I didn't see a need for that.

    I mounted controls on the left and the right so I can operate it from either side.

    I need to draw up an idea and then start reinforcing the base and making a lift platform with a ramp.

    I still need to clean the crud out of the lift, and then put the covers back on.

    I also need to wire a 50A plug in the old garage, because my welding setup is in the new garage, and I don't have an 8/3 extension cord. I don't think my 30' spoolgun will reach either, so I guess I will be running 3/4" conduit tomorrow. I can at least make some mounting tabs and prep the cabinet for welding. I'll borrow a hammerdrill from work for setting anchors.


    The lift raises to 46", so that should be plenty high enough for working on bikes.
    #40