I will be assembling a gate using the cast knuckles and finials you can buy off the web. I would like to know the process/method for attaching the pieces to the mild steel pickets - they are under no load of course. I have searched for information on this but found nothing in detail.If anyone has a site that deals with this process in any detail it would be appreciated.Millermatic® 211 Auto-Set with MVPMiller Diversion 180 AC/DC TIGEvery air tool made...if it can be driven by air, I want it.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Neon Sign Fabricatorwww.casinoneon.com
Reply:I built my ornamental iron/rock fence using mild steel rods and cast iron finials from a place in Louisiana. Used my stick welder with the nickel/cast iron rods and did spot-welds on each side. They don't need full welds, After they cooled, I dipped each end in phosphoric acid, washed them off, then painted them black. They have held up for about 15 years so far. Nothing at all complicated about welding them together.Miller Syncrowave 350Millermatic 252/ 30A spoolgunMiller Bobcat 225g w/ 3545 spoolgunLincoln PowerArc4000Lincoln 175 Mig Lincoln 135 Mig Everlast 250EX TigCentury ac/dc 230 amp stickVictor O/AHypertherm 1000 plasma
Reply:I have seen ornamental iron work with cast alloy decorative trim parts. The grape leaf trim parts came with steel tabs that were migged to the mild steel tubes.I offer three choices: Good, Fast, & Cheap. You may pick two.Hobart AC/DC StikMate LXHarbor Freight AD HoodHarbor Freight Industrial Chop SawDeVilbis 20 Gallon, 5 HP Compressor
Reply:I do a lot of this kind of work and I use nickel rod and just tack them in a place that isn't too obvious. After welding I tap on them with a chipping hammer to relieve any stress just to make sure.
Reply:Ive biult a lot of gates fences and so on. The best way I think, that has ever been done is to tig weld them on with phosphoris bronze. Of coarse you realize the they will break at the weakest point if they get rough treatment anyway so I would just mig them in a couple places. Mac
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lain ol' MIG works pretty well -- even though you're dealing with different metals. (I haven't had any break off, at least.) Just make sure you clean the steel pieces and hit the junction point with a metal brush.Jack OlsenMy garage website
Reply:Thanks - I have been warned about the explosive nature of cast iron, but have welded some to disimilar metals without any issues. I like the idea about trying the nickel & phosphor sticks - will try both out. (Haven't even opened my bronze tube yet.)I really don't want to add any dimension to the item with metal, but have been looking at ornamental work lately and it does not seem to be a concern to anyone - looks like the builder just selects a side to weld and then follows that pattern throughout.Millermatic® 211 Auto-Set with MVPMiller Diversion 180 AC/DC TIGEvery air tool made...if it can be driven by air, I want it.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Neon Sign Fabricatorwww.casinoneon.com
Reply:Glue on finials and regular mig for collars. I use epoxy most of the time. It is hidden too. For collars, I typically tack underneath and weld around the top. Weld all the way around so water won't run between the collar and tube causing rust streaks. I have drilled and screwed one set, though the cast material varies so much. One batch might be easy, and another batch might be harder than drill bits.Plastic finials are pretty nice too, if you are using a common design. The fit well and look nice. Also, I typically dip them prior to welding. Dip in diluted primer. Really helps with final paint and primes the inside where you won't be able to paint.
Reply:If youre doing a lot of finials, grab an old lawnmower wheel or a similiar kind of small open bearing and make yourself a jig. It takes a little practice but you can spin it all the way around and it will look much cleaner. I havent heard of anybody who does lots of ornamental work paying any concern to the dissimilar metal issue. Some cast insets will come with steel tabs, others we welded in a sort of 'cup' fashion around the cast, not actually welding it but holding it in with steel. The finials will come often with slight differences in the inside dimensions, so taking and squaring, at least for 3/4 and down pickets is often counterproductive. The wheel jig helps in keeping them square as well.I think there are ornamental videos on youtube but as always be careful what youre getting.
Reply:Welding cast iron is easy when using the correct rods. I use arc when welding cast you just have to make sure the area to be welded is clean. Another method used is to drill holes and apply iron pins using a chemical anchor to hold together.iron gates
