Log splitter-Stick or Wire?

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Getting ready to build a heavy duty log splitter. It's a true 42 ton(see ruff cad drawing), has a 6 inch I.D. hydraulic cylinder and a 6 X 8 X 0.500 wall rectangular beam. First thought was stick welding the critical welds with thick 7018 rod, but I've been looking into FCAW-G(MIG welding with flux core wire and additional gas, feel free to correct my abbreviations). Did a little research on Dual Shield Welding(ESAB has the dual shield name). Looks like some strong stuff, used in ship, bridge and railroad building....etc. The 42 ton splitter is going to try and rip those welds out, I don't want to re-due this project. I have a  Millermatic 251 mig welder. I'll have to change the drive roll wheels to 0.045 wire size. My local Airgas recommended Dual Shield 7100 Ultra wire. I have a few questions.....thanks in advance...!!!Should I stick weld it(I have a 250 amp DC stick machine) or is FCAW-G the way to go?Is preheat need in both cases(I have OA torches)?Do I have to change the polarity on the Millermatic 251?What settings(Volts-IPM) do I go with on the Millermatic 251?How much gas flow on the Millermatic 251?Is the Dual Shield 7100 Ultra a good wire?Does my Millermatic 251 have enough power and duty cycle to run FCAW-G?Thanks again.
Reply:Is there going to be another flange on the opposite side of the cylinder so that it's in double sheer?There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:I'd go for the duelshield myself. It's far better then stick in my opinion.Dcep, around 25 volts 300imp for 3/8"/1/2" steel. 24/275 for vertical.  75/25 is what I use with that wire. Your 251 is plenty of machine for this.35cfh is good on the gas.Last edited by AKweldshop; 04-08-2015 at 02:08 PM.Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:Yes 2 supports and blade in front of pushplate.
Reply:are these the correct drive wheels ?https://www.airgas.com/p/MIL079607
Reply:Originally Posted by ZZWELDare these the correct drive wheels ?https://www.airgas.com/p/MIL079607
Reply:That's a lot of wire for just one project. While it may be great wire, I doubt I'd spend the money on it just to do a splitter. Stick would be more cost effective in my book. If I was really worried about weld strength, I might opt for 8018 vs 7018, but I doubt on mild steel it would make enough of a difference to matter. ( I know enough guys who use 8018 that I could probably scrounge what I'd need.) I prefer mig, so I'd be tempted to use solid wire in spray mode vs Dual shield. If anything it would probably be cheaper to simply get a gas that would run spray like 92/8, 90/10 etc. vs a 33 lb spool of dual shield. I'd probably get more use out of the gas than the dual shield for what I typically need to do. I also probably wouldn't opt for .045 wire simply because I wouldn't use it enough to matter. I'd stick with .035 unless you are doing super thick steel..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Burn some rods, you know you want toSpend more time dialing the wire in than it's worth, unless you plan on using it often in the future.And stick WORKS.  It HOLDS. It's, it's it's it's ................elegant"Any day above ground is a good day"http://www.farmersamm.com/
Reply:I know what my vote is http://weldingweb.com/vbb/showthread.php...%29&highlight=Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:I would use either one, not a big difference for me. If you use the dual shield and have the M-25 gun be careful with duty cycle to avoid burning up the gun.
Reply:Originally Posted by M J DI would use either one, not a big difference for me. If you use the dual shield and have the M-25 gun be careful with duty cycle to avoid burning up the gun.
Reply:Being that you know next to nothing about duelshield, you'll probably be better off sticking with what you know. Mig or Stick???How experienced are you with hard wire mig or stick?Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:I'd just stick weld the most critical spots.  No need to invest in wire and learning a new process for one small project.If you were going into production I'd feel differently.My name's not Jim....
Reply:Even though you have a 42T ram, are you ever going to get close to actually using that much force? I doubt there are any logs out there that will come close to needing that much pressure to split.  I think you may be over thinking this a bit.Miller Dynasty 200DXMiller 252 Miller 250xMiller Syncrowave 250Miller AEAD200 LegendMiller 375 Xtreme plasmaLincoln WeldPak 100Victor O/A
Reply:W/ a 6" cyl how much pump will you have to get speed and power and how much HP will you need to get both. W/ that much piston area I doubt you'll need that much psi so go for a pump to give you speed. As for the welding, I'd go for stick.                                                 MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:Our wood spliter was built with .035 solid mig wire. 5" cylinder running at 2500 psi no weld problems We bent the 1" thick wedge from northern tool but didn't break the welds. I would weld it with what you are most comfortable using. I have seen some nice wood splitters built with 6011 rods that hold up for years. If you put in a less than ideal weld with wire its is worse than stickMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:Mine is AC stick 5/32 1109 33 years old. Never a crack. I say 1109 cause the locally owned farm store/grain mill was built with this rod, generations of owners made the mistake. I was reading books when I bought my first welder C. 1973 I discovered they were reading upside down. It was 6011. I used a ton of 6011 and 6013.These days I'd opt for the MM252. A properly prepared and welded joint is as strong with MIG, and it takes less skill, It too is low hydrogen, and works easier out of position.An optimist is usually wrong, and when the unexpected happens is unprepared. A pessimist is usually right, when wrong, is delighted, and well prepared.
Reply:Love the Duelshield ultra 7100 that's all we run in the shop rebuilding railcars. Running .045 at 24v and 240imp with a 480v Linde power supply and a Esaab feeder
Reply:Either would work just fine. 75/25 mix gas. Bevel and/or multi pass beads. Duel shield is a really smooth bead don't whip just stringers. Even verticel up now need to weave but a little goes far enough. Get you some scrap and practice 1/2" stick out. Watch your duty cycle on your 251 bc you can run long passes with this stuff. Also watch your hands bc this stuff can get hot.Miller Dynasty 200dxLincoln power mig 255Travel and comercial A/O rigsCheap 7"x14" horizontal bandsaw2 14" abrasion sawsDrill press. Arsenal of grinders/die grindersPower tools Hand tools
Reply:I just called my lws and got some pricing on duelshield. 33lb spool, .045 dia. Price per roll. Wash alloy-----$100 each.Lincoln-----$130 each.Esab----$300 each.No mistypes above.Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:This looks good.....http://www.ebay.com/itm/71T1-1M-FLUX...-/321495807339Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:I built mine using stick... gasp! AC 6013 stick no less. 18 hp kohler and i can kill the motor when i dead head it in a knot... still holding strong!!! I wouldn't feel uncomfortable about using .035 solid wire for yours... Grind your millscale and bevel & preheat your heavy iron and you will be fine. Can't go wrong with 7018 either.. good luck! pics?
Reply:For whats its worth, I'm not a professional just a hobby welder but I built a couple log splitters a small 12 ton using solid .030 mig wire and the second one was a 22 ton horizontal/vertical splitter I used .030 flux core to build both have held up fine, i did do three passes on the critical stressed areas.
Reply:I learned on Lincoln duel shield and ran esab at work for your shop the Lincoln would be more then adequate. No experience with the other stuff.Miller Dynasty 200dxLincoln power mig 255Travel and comercial A/O rigsCheap 7"x14" horizontal bandsaw2 14" abrasion sawsDrill press. Arsenal of grinders/die grindersPower tools Hand tools
Reply:I think you are worrying too much. Ours was built over 15 yrs ago and runs off tractor hydraulics with no problems. I welded it with my Forney AC buzzbox and 6013 and 7014 rods. Use what you are comfortable with and do it well. Most rods will have a higher tensile strength than the metal you are using so just make sure you get some decent welds.250 amp Miller DialArc AC/DC StickF-225 amp Forney AC Stick230 amp Sears AC StickLincoln 180C MIGVictor Medalist 350 O/ACut 50 PlasmaLesBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Use the stick luke it has worked since my fathers time it will work now  ..Bevel and root well..This is what i us 1/8 for  then fill and cap with that box of rod you were looking to buy Who's your daddy Backed my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:Looks like it's going to be stick welded. Probably not a good time to go through the full learning curve of FCAW-G just for this splitter. Catastrophic failure is not an option here. FCAW-G looks very interesting, will look into more on other projects. @ AKmud: We have Eucalyptus trees out here in CA. Eucalyptus firewood burns long and hot. Some trees grow over 4 feet in dia. and over 60 feet high. It's a very tuff wood to split, with a very nasty twist in it. Smaller hydraulic log splitters just can't split it, stops them dead in their tracks as soon as the blade touches the wood. Split and dried, Eucalyptus firewood sells for over $500.00 per true full cord. This is going to be a real, hard core test on my welds, hope they hold !!! Thanks all for your input/comments.
Reply:Set up with an .035 solid wire and C-25, that MM 251 offers plenty of power for this type of project.ESAB Migmaster 250 Hobart Ironman 230Multimatic 215TWECO Fabricator 181i & 211iHH125EZ - nice little fluxcore only unitMaxstar 150 STH - very nice
Reply:42t for a log splitter..dammm  you guys have hella hard wood in your area!
Reply:@ ZZ - stick, based on your disclosed current skill set and time horizon.  Stick's Boss "Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Originally Posted by ManoKai@ ZZ - stick, based on your disclosed current skill set and time horizon.  Stick's Boss