Date: Sun, 16 Mar 2008 09:00:52 -0700
Reply-To: neil N <musomuso@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: neil N <musomuso@GMAIL.COM>
Subject: Re: WAS: building carrier bar..... NOW: Test Weld PIC
In-Reply-To: <0fc401c8877d$dfde9ff0$0a00a8c0@OWNERMIKE>
Content-Type: text/plain; charset=ISO-8859-1
Thanks Mike! :)
Neil.
On Sun, Mar 16, 2008 at 8:53 AM, Mike <mbucchino@charter.net> wrote:
> It's definitely a good idea to cut one cross-sectionally to demonstrate
> penetration. You do need 100% penetration; this can be achieved by
> V-notching the thickest parts before welding, even if it means laying down
> more than one bead to fill the gap completely. This is how the thickest
> metals are commonly joined by welding professionals.
> One way to judge if you've achieved 100% weld penetration, is to look at
> the backside of the joint; if you can clearly see an even, 'heated' stripe
> of discoloration in backside of the base metal, you've got it.
> If you have thick, rounded 'mountains' of filler metal standing above the
> base metal, there's not enough penetration, and the joint will be weak and
> will crack.
> If you have thin 'valleys' of melted base metal, there's too much heat and
> not enough filler; possibly undercutting and weakening, even to the point of
> 'blowing-through' in spots. This too will be weak and will crack.
> It's this delicate balance of proper heat, filler and penetration that
> takes lots of practice to achieve, and the procedure differs for
> butt-welding, lap-welding, corner-welding, vertical-welding, tube-on-tube,
> tube-on-plate, different thickness materials, thick -to-thin metals, TIG,
> MIG, oxy-acetylene, etc.
> Have fun and get lots of practice, and some critiqueing from experienced
> welders.
>
> Mike B.
>
>
>
> ----- Original Message -----
> From: "neil N" <musomuso@GMAIL.COM>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Sunday, March 16, 2008 11:07 AM
> Subject: Re: WAS: building carrier bar..... NOW: Test Weld PIC
>
>
> > Thanks again Gary.
> >
> > I've been pushing my welds. Was considering pulling so I could see the
> > puddle better, but I'll stick with the programme. Good tip on pre
> > heating. As for wiring etc., I don't use an extension, but I did find
> > that with the welder set to max. and my big fan on max, that the
> > circuit will overload! (can a guy weld in the dark? --- ;^)
> >
> > I can sort of "see" that the penetration on 1/4", even if welding
> > optimally, would be limited. I'll bet that at best, it's only going in
> > about a 1/3 of the way. I should cut open a 1/4" weld and see.
> >
> > Appreciate the help. And nice lookin' Vanagon bike racks!
> >
> > Cheers,
> >
> > Neil.
> >
> > On Sat, Mar 15, 2008 at 11:14 PM, Gary Lee www.vwrack.com
> > <gary2a@telus.net> wrote:
> >> Well gas will be cleaner than flux, but not necessarily stronger. If you
> >> only weld occasionally, I would not bother with renting or buying a gas
> >> bottle.
> >> Good you got lots of amps available. That makes a big difference.
> >>
> >> 120 volt welders can't produce enough heat to weld 1/4" 'properly'.
> >>
> >> To maximize the amount of heat a small welder will produce:
> >> - Heavy gauge extension cord
> >> - Hold tip as close to work as possible
> >> - Push the bead, as opposed to pull. Push = like driving forward. Pull
> >> =
> >> like driving in reverse
> >> - Preheat the piece with a propane or acetylene torch
> >> - Move torch slow, steady and smoothly. In a controlled motion.
> >>
> >> fwiw, I wouldn't be welding any trailer hitches with a 120 volt welder.
> >>
> >> If anybody in Calgary needs simple welding jobs like that done, I do it
> >> for
> >> free for local vanagon owners.
> >>
> >>
> >> Gary Lee
> >> www.vwrack.com
> >>
> >>
> >>
> >> ----- Original Message -----
> >> From: "neil N" <musomuso@gmail.com>
> >> To: "Gary Lee www.vwrack.com" <gary2a@telus.net>
> >> Cc: <vanagon@gerry.vanagon.com>
> >> Sent: Saturday, March 15, 2008 11:44 PM
> >> Subject: Re: WAS: building carrier bar..... NOW: Test Weld PIC
> >>
> >>
> >> > Thanks for the pointers Gary.
> >> >
> >> > Yup. 120, MIG with flux but am running 12 gauge from a 20 amp breaker.
> >> > I found I could go quite slow on the 1/4" plate and will slow it down
> >> > more. Quite a contrast to the practice welds I tried on the scrap
> >> > exhaust tube.
> >> >
> >> > I may end up using 1/8" plate and angle instead of the 1/4". Those
> >> > were free scrap pieces so I gave it a whirl.
> >> >
> >> > I'm learning pretty fast, but there's lots to learn even with just
> >> > setting up correctly. Proper lighting, material and work position etc.
> >> >
> >> > It'll be nice to get set up with gas. The flux puts out too much smoke
> >> > and spatter.
> >> >
> >> > Thanks,
> >> >
> >> > Neil.
> >> >
> >> > On Sat, Mar 15, 2008 at 10:30 PM, Gary Lee www.vwrack.com
> >> > <gary2a@telus.net> wrote:
> >> >> >Now I KNOW I'll get this load bar done. Too bad I can't get
> >> material
> >> >> >til Tuesday!
> >> >>
> >> >> > http://tubaneil.googlepages.com/1stlargeweld
> >> >>
> >> >> >Thanks guys,
> >> >> >Neil.
> >> >>
> >> >> Neil,
> >> >> Looking at your picture, I'd say you are using a 120 volt MIG.
> >> >> Fluxcore?
> >> >> That would give you marginal penetration on material as thick as in
> >> >> your picture. Go slowly and weave back and forth. I hold the torch
> >> >> with two hands, one on the trigger and the other near the tip. Hold
> >> >> the torch close in to the material, as little 'stick out' and
> >> >> possible. Plug your welder in as close to the breaker box as
> >> >> possible. Avoid using extension cords.
> >> >>
> >> >> Gary Lee
> >> >> www.vwrack.com
> >> >>
> >> >
> >> >
> >> >
> >> > --
> >> > Neil Nicholson. 1981 Air Cooled Westfalia - "Jaco"
> >> >
> >> > http://web.mac.com/tubaneil
> >> > http://tubaneil.googlepages.com/
> >> >
> >> >
> >> > --
> >> > No virus found in this incoming message.
> >> > Checked by AVG.
> >> > Version: 7.5.519 / Virus Database: 269.21.7/1329 - Release Date:
> >> > 14/03/2008 12:33 PM
> >> >
> >> >
> >>
> >>
> >
> >
> >
> > --
> > Neil Nicholson. 1981 Air Cooled Westfalia - "Jaco"
> >
> > http://web.mac.com/tubaneil
> > http://tubaneil.googlepages.com/
> >
>
>
--
Neil Nicholson. 1981 Air Cooled Westfalia - "Jaco"
http://web.mac.com/tubaneil
http://tubaneil.googlepages.com/
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