Seiler's Fab/Welding thread.

[Seiler]

Hey guys,

First - I wasn't sure if this specific forum was appropriate for this thread. I wanted to have a place where I could document all my welding and fabrication stuff on within the CO chapter area. I had contemplated starting this in the "Other Rides and Builds" sub-forum, but since this isn't dedicated to one single project I decided to put it in the main forum.

Please move this to the appropriate area if need be Moderators. atriot:

Quick info -

My name is Scott, I've been on for awhile now. I got sick of not being able to weld on my own projects, so I went to school for it and finished earlier this year. I'm Currently employed in Boulder where I TIG Stainless and have been doing so for almost 2 years now. I'd love to show you guys some stuff I do at work, but there is a no camera rule on the floor so that's out the window. :laugh:

Picked up my own TIG/Stick welder a few months ago and finally have my first real project worth showing!

If you guys have any questions or comments please feel free to join in. I will try to keep this thread updated with personal projects and what's related. I am not looking for or seeking business, merely sharing some of my work with you fine folks. :cheers:

Without further ado, here's the new toy -



DSC_3672 by The Color Orange, on Flickr


DSC_3694 by The Color Orange, on Flickr


DSC_3701 by The Color Orange, on Flickr

Scott

 

[Seiler]

To start, my first project has been a welding/fab table. I knew I wanted something I could BEAT on. I did a lot of research on GarageJournal, WeldingWeb and other forums/galleries throughout the internet. So, for my materials I chose:

-20' of 2" x 2" x .188" wall square tubing
-20' of 3" x 3" x .250" wall square tubing
-48" x 36" x .750" thick A36 plate

At the end of the day the table needs to snug up in a corner for safe keeping which explains the 48" x 36" plate size. I also wanted the table to roll around with ease. I purchased four 6" Fairbanks casters from Northern Tool (two swivel and two rigid) rated for 900 lbs each.

I wanted a simple, strong design for the base with a final height of ~36" with 3.5" of overhang. The primary use of this table will initially be TIG and/or stick welding.


IMG_1504 by The Color Orange, on Flickr


IMG_1505 by The Color Orange, on Flickr

At first I cut everything into pieces 1" bigger than they needed to be with my portaband. I quickly began to realize I could not achieve a straight cut to save my life so this is where the Dewalt comes in. Time to make some noise and spit some chips.


DSC_3844 by The Color Orange, on Flickr


DSC_3845 by The Color Orange, on Flickr


DSC_3846 by The Color Orange, on Flickr

This saw is my first Dewalt tool (aside from a few drill bits). As for dry cut metal saws, there aren't a whole lot of options to purchase these in person that I could find. There's always the option to order something different online and wait for shipping, however at this point I was growing impatient and wanted to begin. Overall the saw cuts very well and definitely made this project easier than it could have been. I would recommend the tool to others, but only if you're willing to shell $450 for this thing.

All done!


IMG_1480 by The Color Orange, on Flickr


DSC_3849 by The Color Orange, on Flickr


DSC_3856 by The Color Orange, on Flickr


DSC_3861 by The Color Orange, on Flickr

 

[Seiler]

After all the cutting I decided to lay the plate flat on something allowing me the ability to move it around the garage floor. I knew the plate was the only surface I had that was large enough and closest to flat enough to build this base on.

I purchased a furniture dolly from HD for $20 and it worked perfect.


DSC_3854 by The Color Orange, on Flickr


DSC_3855 by The Color Orange, on Flickr

I built the frame upside down In order to keep it as square and solid as possible. I knew once it was completely assembled I could easily take a grinder to the "bottom" of the legs in the event there was a wobble from something being off.

The plate itself measures 47 15/16 in. x 35 15/16 in. I picked and used a corner to base all my measurements from.


DSC_3857 by The Color Orange, on Flickr


DSC_3858 by The Color Orange, on Flickr

Then I laid out my legs and the "top" of the frame.


IMG_1490 by The Color Orange, on Flickr

Marked what had to be sanded.


DSC_3880 by The Color Orange, on Flickr


DSC_3890 by The Color Orange, on Flickr


DSC_3885 by The Color Orange, on Flickr

Aaaaaaaannnd labeled all the pieces.


DSC_3872 by The Color Orange, on Flickr


DSC_3874 by The Color Orange, on Flickr


DSC_3875 by The Color Orange, on Flickr

 

[Seiler]

Nothing makes TIG welding easier than clean, shiny metal!


DSC_3898 by The Color Orange, on Flickr

Time to start tacking.


DSC_3904 by The Color Orange, on Flickr


DSC_3908 by The Color Orange, on Flickr

Next leg.


DSC_3913 by The Color Orange, on Flickr


DSC_3910 by The Color Orange, on Flickr

And I eventually got sick of taking pictures between every leg. You get the idea. All tacked.


DSC_3917 by The Color Orange, on Flickr


DSC_3921 by The Color Orange, on Flickr


DSC_3923 by The Color Orange, on Flickr


DSC_3926 by The Color Orange, on Flickr

Best part? No wobble and solid as a rock.

I then started on the bars between legs.


DSC_3930 by The Color Orange, on Flickr


DSC_3931 by The Color Orange, on Flickr

Did the same on the other side.

 

[Seiler]

After going up and down, and up and down all day... Grinding, moving metal, lifting, pushing, pulling etc. I had to put up a fight with the last bar that went long ways near the bottom. I was least interested at this point in taking pictures.

Which leads me to the base being all tacked.


DSC_3938 by The Color Orange, on Flickr


DSC_3940 by The Color Orange, on Flickr

Unfortunately, that's as far as I got this week. I work weekends and won't be able to continue until next week. I will keep you all updated!

Scott

 

[jdxj]

Looking good man, looks like you'll be able to park a 747 on that thing with more than enough strength to spare!

 

[Kittrell]

 

[eflores]

i concur

 

[time2getdirty]

Nice welder! I am trying to get rid of my Miller 180 tig welder as it is too small for me, I should have waited for the 200dx like that!

 

[Boostwerks.com]

Hey guys,

Without further ado, here's the new toy -


http://www.flickr.com/photos/30469983@N04/9951562123/
DSC_3672 by The Color Orange, on Flickr


DSC_3694 by The Color Orange, on Flickr

http://www.flickr.com/photos/30469983@N04/9951430295/
DSC_3701 by The Color Orange, on Flickr

Scott

OMG. :loveu:

So Jelous! I'm still using a dinky Maxstar 150. Those Dynasty's are the bee's knees.

 

[Hypoid]

I'm glad you are putting wheels on that heavy beast. I get tired just looking at it.

 

[Seiler]

:laugh: Everytime.

Nice welder! I am trying to get rid of my Miller 180 tig welder as it is too small for me, I should have waited for the 200dx like that!

I feel very, very spoiled being able to afford this machine. Right after I bought my machine though, Miller released the Dynasty 280's. I had a really hard time deciding between the 200DX and the 350. A 280 would have been PERFECT. :banghead:

OMG. :loveu:

So Jelous! I'm still using a dinky Maxstar 150. Those Dynasty's are the bee's knees.

Miller is all we use at work, I had to own one. I've used Lincoln, ESAB and Thermal Arc. Honestly, had I not been able to afford the Miller I would have went with a Thermal Arc. I don't like the ESAB or the Lincoln's TIG performance at all.

I'm glad you are putting wheels on that heavy beast. I get tired just looking at it.

Me too! You want to come over and help me move it around before the casters go on?

I didn't get a chance to work on the table today. I need to source a few Irwin 18SP clamps before I begin welding. Only friggin' place around here that has any in stock is Matheson Trigas off I-70. None at HD, Lowes, Ace, Murdochs etc.

Side note - I would highly recommend Matheson (formerly Linweld) to anyone in need of a LWS visit. SO much better than Airgas and their pricing is fantastic. I will NEVER go to Airgas again.

Scott

 

[Hypoid]

You want to come over and help me move it around before the casters go on?

Sure! I bring my hoist and moving dollies. Then, I'll help you move those Wiltons around and into my truck. :loveu:

 

[Seiler]

Sure! I bring my hoist and moving dollies. Then, I'll help you move those Wiltons around and into my truck. :loveu:

Pffffffffffft.

Update!

I started with the "top" of the base. I took a few minutes to grind a slight groove for the weld to penetrate a little better.


DSC_3952 by The Color Orange, on Flickr

My dad is into woodworking and has more clamps than anyone I know. I asked if I could borrow a few and he was more than happy to lend them out. So, I clamped a few sides.


DSC_3961 by The Color Orange, on Flickr


DSC_3960 by The Color Orange, on Flickr

Laid a few beads on the top.


DSC_3967 by The Color Orange, on Flickr

I then flipped the base over and clamped the "top" to the plate. This is the orientation the top plate and base will attach against one another in the end.


DSC_3978 by The Color Orange, on Flickr


DSC_3979 by The Color Orange, on Flickr

Here comes the real fun!


DSC_3986 by The Color Orange, on Flickr


DSC_3989 by The Color Orange, on Flickr


DSC_3991 by The Color Orange, on Flickr

I had to use my knee for the foot pedal more than ever today. Finding a comfortable position proved to be a challenge. I got through it though and now my knees are killin' me. :laugh:

 

[Seiler]

Results:


DSC_3994 by The Color Orange, on Flickr


DSC_3995 by The Color Orange, on Flickr


DSC_3998 by The Color Orange, on Flickr


DSC_4011 by The Color Orange, on Flickr


DSC_4018 by The Color Orange, on Flickr


DSC_4020 by The Color Orange, on Flickr

I had a few fun vertical ups for fun as well.


DSC_4027 by The Color Orange, on Flickr


DSC_4036 by The Color Orange, on Flickr


DSC_4049 by The Color Orange, on Flickr

It has been a little while since I've welded on plain carbon steel. I forgot how much heat you can pour into this material. I still have 24 more welds to complete tomorrow. I'll post pictures after those are finished and the base is complete.

Cheers everyone, time for bed.
:cheers:

 

[eflores]

excessive is the word im looking for....very nice

 

[Fred]

Just out of curiosity, how long does each weld take? I wouldn't put wheels on it, what I miss the most is a flat table that won't move despite any leverage I apply to it. And don't forget, despite the beautiful welds, it's only worth $0.07-0.12/lb. You could probably spend a little less time on each weld. Just saying.

 

[SleeperXJ]

I'm going to guess 10 seconds per weld.
Prep and setup I is where the time goes.
Seiler, are you using the Dynasty 200 running 115 vac?

 

[xj5280]

Pure sex!

Love the attention to detail; all the way from design, prep, to finish welds. Also love the photo quality too. Makes it that much better! Keep up the good work.

 

[Seiler]

I'm feeding with 1/16" rod, so each weld takes about 25-30 seconds. I could have purchased 3/32" rod but meh, I like the puddle control and appearance of using a smaller rod diameter. Honestly, I thought about welding the entire thing out with 7018 because I have a bunch, but stick just isn't fun for me like TIG is. What I'm doing isn't efficient, but half-assing or not taking my time on these welds goes against my attention to detail and who I am as a person. If it doesn't look damn near perfect then I don't like it and I would get upset every time I look at it. :kissyou: :laugh:

The casters are going on just so I have the ability to move the thing around (it's forecasted to weigh in around 700 lbs when it's done). I don't have the setup for a stationary bench. I do plan to fab up some adjustable padded feet so I can level the bench out after I move it to where I want it.

SleeperXJ, I have the welder plugged into my dryer's 220V outlet and my Coolmate is plugged into the 115V feed.

Thanks for the feedback guys, I appreciate it.