Quick bumper bracket question

Tue, 31 Aug 2021 09:44:30 GMT

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I'm currently welding up a bumper for a '94 Jeep YJ, and have a quick question on welding in the mounting tabs.  The main portion of the bumper (which will serve as the shell for the build) is 3x4" 1/4" angle.  I have three brackets cut out of 5/16" plate, which are bolted to the frame, and the plan is to have the bumper easily removable from the brackets.  I'm using 0.25" thick 2" flat bar as my bolting tabs, basically 6x of them with 2x 7/16" holes to bolt the bumper to the brackets (3x on the bumper and 3x to the brackets).  I'm using a Miller Multimatic 215 with .030" solid wire, 75/25, and 20.5v with 465ish IPM.     Here is my question.  Because the tabs fit so tightly, I only have room to weld on one side.  Question is, will it be sufficient?  I could weld to both sides, but that would require me cutting down each tab to accommodate the weld bead.  Here are a few pics to give you an idea of what I'm trying to explain:
Reply:You would want a full bevel on the one side, and your wire is a bit skinny for the thicknesses of plate you are welding.As far as, are they sufficient? Sufficient for what? Mounting a jack to? Sure. Heavy winching? Absolutely not, you’ll want full penetration welds both sides if it is going to be heavily abused.
Reply:You could have chamfered the inside of the tab you welded on. Chamfered both sides actually. But what ever. A bevel on the inside would have let you run a good bead back in there that wouldn't protrude too proud into the bolt up area. The have a ball on the outside. Good time to work on when and where beveling helps."The things that will destroy America are prosperity at any price, peace at any price, safety first instead of duty first, the love of soft living and the get rich quick theory of life." -Theodore Roosevelt
Reply:You would want a full bevel on the one side, and your wire is a bit skinny for the thicknesses of plate you are welding.
Reply:Weld the tabs all the way around. Just hit the end of the other mating tabs with course flap wheel. Wouldn't take much to make room for the weld. Should have just cut them shorter or drilled the holes so the ones attached to vehicle didn't get anywhere close to the weld. Dual 7/16" bolts at each tabs and the friction between the two tabs should be enough to maintain level.
Reply:If that's the design of the final bolted connection it would rip that Jeep to shreds before it came apart.www.urkafarms.com
Reply:Originally Posted by SberryIf that's the design of the final bolted connection it would rip that Jeep to shreds before it came apart.
Reply:Trick to weld design is designing to the base metal.Lotta stuff about the Ksi of the filler...……………………..doesn't matter You need to look at the base metal.  If it's A-36, figure out the square inches of weld, and calculate the strength based on the base metal.1/4" fillet, 4" long, yields about 1" of useable weld.  Which equates to 36Ksi strength.  I don't care how strong your filler metal is...………...it all boils down to the yield point on the base metal.Then, you calculate your moment, and see if it comes too close to 36Ksi.  Should be about 4x the base metal yield point.
Reply:Then ya gotta figure the plate orientation.  Is it on the end grain, or is on the laminated surface.  Laminated surfaces tend to tear...……...it's the mill process.  Rolling steel makes lamination bands.
Reply:Then,, when you're happy...……..throw the MIG out in the driveway...…….and either pick up the stinger, or load some Outershield in the wire machine.
Reply:You can do what your neighbor did (and maybe it worked), or you can do it smart.Most stuff is user critical...……...fails, and ya get a not-so-free trip to the ER.  Be the metal.Internet is full of "I did this,, and it works"...…..without verifying proof.Get some books, and some software, and apply them, with a grain of salt.Keyboard commandos gonna tell ya anything ya wanna hear...……….beware.  Do the math.
Reply:.fails, and ya get a not-so-free trip to the ER.
Reply:So...………..you're toolin' down the highway...…...blissfully thinking that your number isn't up yet  Nothing really has a real impact on yer safety You pull in behind me...………………………….Aren't ya glad I put some thought, and a bit of minor testing, into the design of that custom pivoting ratchet that's holding that angled strap? I could be a real p@ick, and say that it's only cause I don't want my insurance rates to go up if'n that coupla bales go thru yer windshield.  But...……..I actually care about my fellow Man, so I get anal to the 9th degree.At Uranus, We care about how it comes out.
Reply:Thank you sammmm for caring about my anus!IMPEACH BIDEN!NRA LIFE MEMBERUNITWELD 175 AMP 3 IN1 DCMIDSTATES 300 AMP AC MACHINEGOD HELP AMERICA!“Freedom is never more than one generation away from extinction.We didn’t pass it to our children in the bloodstream".RONALD REAGAN
Reply:Thanks...………………….We like to say, here at Corporate...…………...we got your 6
Reply:I agree this would be a different issue if this bumper was hooked to the semi but this is a Jeep.  The fact  that the rest of it is overbuilt is irrelevent, still hooked to a Jeep frame.www.urkafarms.com
Reply:still hooked to a Jeep frame.
Reply:I know this post in a tab bit old...But what I would do and what I have done..Is find out where it lines up on the back side of the mounting plate. Drill holes in the plate (back side) of the where the tab is welded and plug weld it also...But that set up is only going to be as strong as the hardware (boltage)....Welds last longer than Love...
Reply:If I had it to do over again, I would have notched the vertical piece of the angle and extended the tab all the way through....that way it could have been welded on both sides.  Granted, its not because I think its necessary in this application, its just that it would have been the most ideal way.