Welding Projects and Progress


3/6 - I had to hunt around to find a small tool box for the extra tips, striker, cutters and other basic tools. I didn't want a large tool chest. I used pop rivits to secure the tool box, in case I want to switch to a different one. I may add a couple of pieces of 1-1/4" pipe to hold welding rods.


 3/5 - I also added brackets for the hoses.


3/5 - I added brackets on all 3 posts to use chain for securing the tanks. With 2 tanks just the outside posts are used.


3/4 - Here is the cart with the tanks in position.
 


 


 

The base plate and handles are welded into place.





3/3 - I welded the brackets to the axle. It was fairly easy to position them and true them up.






3/1 - In class Toby said to use the #2 tip to heat the brackets for bending. I would have used the 'rosebud' tip, which he said would have heated too large and area.


3/1 - I submitted paperwork for a Design Patent. Hope I got everything right!
       


2/23 - I have a request for a larger handle on the litter scoop so I picked up some 1" square stock. I also tackled a different way to weld the expanded metal. I used old pieces and it came out pretty good. Lisa is testing it for 'feel.'
 


And I took a pass at welding the cross piece with the channeled ends, Again using scrap, the weld came out pretty good, but needed some grinding to even out the weld.


2/22 - drilled 3/4" holes for the axle. It rained today, so I didn't have access to my vise and torch to make the bend for the part that will attach to the axle.


2/21- The wheel bracket is an interesting piece. It holds the axle and moves the wheel back a bit from the uprights. I looked at quite a few hand trucks and it's about 50/50 with axles welded to the uprights and axles moved back. It seems to me that when it's welded to the frame, there might be better initial leverage, but the balance point is pretty vertical. So I decided to move the pivot back a bit since the largest tank is about 5 feet tall.
 


2/20 - The hand truck I'm modeling this after, has handles to help in the tilting. Again, I am channeling the ends for a smoother fit.


2/17/04 - I worked on the middle upright brace. The model I'm working from flattens the round pipe to weld it at 90 degrees to pipe. It looks a lot better if the pipe is channeled to fit the roundness.


I also finished up the wheels, grinding out two more washers for the outside of the wheels.


2/16/04 - I took all the parts to class and Toby thought all were usable. I told him I wanted to try to get smoother bends. So he said he would show us how to use a 'rosebud tip' to heat metal. With him on the torch, we heated the pipe to a glowing red. Then I put it in the jig and began the bend with even pressure. We heated it several times and finished the bend. It looked very good by comparison. So I tried another one by myself. It's difficult to heat it, then turn off the torch, put it in a secure position, pick up the pipe, put it in the jig, hold it and bend it. I ended up with one kink, better than the other ones I did, but it still had a kink. Toby helped me do another one and it was a match to the first one. Toby conceded it was a two person job.

Old

New


I also worked on the wheels. I had the axle and tires. I had to drill holes for retaining cotter keys. The drill press in class was better tan trying to do it with a hand drill. It worked like a charm.


2/12/04 - Welding Cart for Oxy/Acetylene tanks

2/13/04 - Today I worked on the handles. These will be welded to the back of the upright pipe. I had to bend the pipe in a similar manner as upright support. I used the same board and mounted a new bend pattern.


2/12/04 - Welding Cart for Oxy/Acetylene tanks

My project for Welding class is a cart to hold the Oxy/Acetylene tanks. I have been using my hand truck which will do in a pinch, but it would help to have a tool box and some hooks on the cart. I did a drawing based on the hand truck, modifying it to accommodate the larger size required. The base plate was made on 2/4 when I cut a larger piece. Today, I took a shot at making the handle. Toby, the instructor reinforced the idea I had as to how to achieve the bend, so I went out and got the parts to bend the pipe at home. My second pass came out pretty good.
 


 


 



2/10/04 - Grinder Stand

Another project in the book was a table for a grinder. I just happens that I had a grinder from over 10 years ago, that I never used because I didn't have any place to mount it. By this time I had started a class at UCSD and was exposed to Oxy/Acetelene Welding and cutting. On 2/6 I bought some scraps and used the 'cutter' to get the top and base to the right size. The metal was 1/4" and 1/2 " so I decided to use gas to weld it. At first, I couldn't get the base plate welded to the upright square post. I figured it was because the base was 1/2" and the welding tip I had wasn't big enough. So I welded the top plate, which was the mount for the grinder. That went pretty well, except the plate bent. I checked with the instructor the next time I went to class and he said sometimes you can get the metal too hot and have to take a break between welds. He thought I should be able to MIG weld the base, but I described the limitations of my unit due to not using gas with the MIG.

In that same class session, we got exposed to the old method of stick welding or arc welding. The process burns very hot, fast and is very smoky. It became clear as I watched the others change between arc and MIG welding that one of the keys is making a 'test run' before actually welding, regardless of which type of welding one is doing. I watched two of the other students MIG weld and they did very well compared to me, but I began to pick up the technique as they explained it to others.

The next morning I pulled out the MIG welder and did a test weld on the 1/2 inch plate based on what I had learned the night before. It developed a puddle. A couple more passes gave me the confidence to tackle the grinder platform. So I positioned the parts and welded the two pieces together. It came out pretty good and will certainly do the job.

I still have to work on a way to 'see' what I am doing when I am MIG welding. Several other students have the same problem. The lens is a #10 to protect your eyes which is very necessary, but it's so dark, it makes it very difficult to weld. If I'm outside and the the sunlight is shinning on the work, I can see pretty good.


2/4/04 - Welding Cart for Oxy/Acetylene tanks

My project for Welding class is a cart to hold the Oxy/Acetylene tanks. I have been using my hand truck which will do in a pinch, but it would help to have a tool box and some hooks on the cart. I did a drawing based on the hand truck, modifying it to accommodate the larger size required. The base plate was made when I cut a larger piece. I had a few questions for my instructor on 2/9.


 


 


 


 


2/4/04 -Cutting
We learned how to cut metal with an oxy/acetelyne torch in welding class. So I tried it at home. My first pass was OK, then I went downhill from there. It took a while before I figured out I was too close to the material with the torch. The first piece I cut is for my next project.


12/24/03 - Welding Cart
In the first book regarding welding the writer listed some projects in the back of the book, commenting that the welding cart should have been the first thing he built in his welding career. So having read his section of MIG Welding a looking at a video, I put together this cart. I use it every time I weld...


1/20/04 - Heavy Duty Litter Scoop
By this time and several iterations, I changed the handle to square pipe. I took these into class and Toby, the instructor was impressed. I explained that I was having problems with the MIG and really burning the expanded metal. He suggested that I use 'brazing', which he would try to show us at a later date.


1/6/04 - Heavy Duty Litter Scoop
For my second pass, I used EMT Electrical conduit. I later found out that the coating they put on the conduit is very dangerous. Fortunately I was spot welding more than I was really welding.

12/23/03 - Heavy Duty Litter Scoop
My first attempt at welding was trying to make a heavy duty cat litter scoop which was requested by several friends in their frustration in dealing with plastic litter scoops. I came up with a design using 'expanded metal' that would need to be welded to a handle. The very first one used a garden trowel handle and some scrap expanded metal.