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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
Comments: To: Mike <mbucchino@charter.net>
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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