Aluminuim Stage truss

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Hello to all , i have been lurking around this forum for a while now , and i have picked up a lot of info regarding welding AL with a proper TIG machine, i have my mind pretty much set on a Miller dynasty 200 DW with a water cooled torch to build this stage truss ......My question is , has anybody build something similar ? I have experience with a MIG machine , (automotive industry) .But i just saw the pricing on stage truss , and the way i am , i like to do things for my own,Im not building a huge stage , something i can build between me and 3 other workers...Something like this...Let me know if In the right direction.....Greeting to all
Reply:Are any of you structeral engineers that can evaluate static and dynamic (wind) loads, etc., as well as safety factors? And unless you are to be the only ones under it, how's your insurance? Welding certs? Are you prepared to do destructive testing to verify your designs?No? Run (not walk . . ) away!Your picture shows a big sail and almost zero tie/hold down.  It can't realy be done much more poorly.  Google "Indiana state fair stage collapse" for an example of how the pros don't always get it right, and they had *TONS* of anchors and cross braces!I run a modest production business, and myself, have always regarded truss prices as low for what you get . . . and typically one of the least expensive parts of the overall system.  And I don't run anything nearly that small - we usually have 3000 lbs or more up in the air, all on load rated, non-Chinese rigging and chain motors, with minimum 5:1 safety factors.  Oh, and be aware, on most truss, ding it more than 1/32" in depth, and that stick just became scrap . . .- TimLast edited by tadawson; 08-26-2013 at 04:05 PM.
Reply:What you have pictured is call DJ or decorative truss. You can buy it cheaper than you can make it. The wall thickness on that stuff is 1/16th inch. You see alot of that stuff coming out of China these days, made with cheese tube and 4043(bad).Are you wanting triangular truss or box truss? You will be surprised what you find on Fleabay.Weld like a "WELDOR", not a wel-"DERR" MillerDynasty700DX,Dynasty350DX4ea,Dynasty200DX,Li  ncolnSW200-2ea.,MillerMatic350P,MillerMatic200w/spoolgun,MKCobraMig260,Lincoln SP-170T,PlasmaCam/Hypertherm1250,HFProTig2ea,MigMax1ea.
Reply:You would also be amazed how much of it is damaged beyond repair . . .- Tim
Reply:There's not much to say in welding it- it's welding- you can either do it or not.( I'm not discounting the safety stuff-it has already been mentioned)But let's say you can weld it- do you also have the machinery to make the connection points as well as the couplers to connect the Top Frame to the Columns?It is just basic math now with figgering out the amount of material you are going to need, pricing it and then comparing it to the cost of buying a manufactured Truss system.Ed Conleyhttp://www.screamingbroccoli.com/MM252MM211 (Sold)Passport Plus & Spool gunLincoln SP135 Plus- (Gone to a good home)Klutch 120v Plasma cutterSO 2020 benderBeer in the fridge
Reply:Originally Posted by tadawsonYou would also be amazed how much of it is damaged beyond repair . . .- Tim
Reply:Beyond all the safety stuff, alum tig is fairly tough to do, and do well. Now you want to do out of position tig welding alum on thin round tube on tube clusters. You are talking about learning to juggle while riding a unicycle blindfolded on a tight rope while juggling chainsaws and feathers... You probably couldn't come up with a harder combination to try and start out with. Figure at least 1000 hours of good solid practice minimum with instruction, if not more. Most of the students I work with I'd bet that number would be almost double that.By the time you add up the machine, the electric, gas, rod and all the practice material, I bet you'd find the premade stuff "dirt cheap" in comparison. If you are doing it DIY without instruction, take that figure for practice and at least triple it..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:Originally Posted by DSWBeyond all the safety stuff, alum tig is fairly tough to do, and do well. Now you want to do out of position tig welding alum on thin round tube on tube clusters. You are talking about learning to juggle while riding a unicycle blindfolded on a tight rope while juggling chainsaws and feathers... You probably couldn't come up with a harder combination to try and start out with. Figure at least 1000 hours of good solid practice minimum with instruction, if not more. Most of the students I work with I'd bet that number would be almost double that.By the time you add up the machine, the electric, gas, rod and all the practice material, I bet you'd find the premade stuff "dirt cheap" in comparison. If you are doing it DIY without instruction, take that figure for practice and at least triple it.
Reply:Im aware of the loads im going to put this stage through, lest then 2000 pounds , being , 4 lighting fixtures (movers) , a pair of high end speakers flown and some other things , yes the stage will be anchored ,Im prepared to make a Jig for making consistent truss sections.I know its not a easy task , but im willing to put in the time (and money) to make a proper truss section.the connecting joints will be made in a proper milling shop a few block away ( down the road, id love to buy machinery to make these myself).Shovelon could you give me some pointers?Last edited by Limeweld; 08-26-2013 at 11:22 PM.Reason: spelling
Reply:Originally Posted by LimeweldShovelon could you give me some pointers?
Reply:Originally Posted by DSWBeyond all the safety stuff, alum tig is fairly tough to do, and do well. Now you want to do out of position tig welding alum on thin round tube on tube clusters. You are talking about learning to juggle while riding a unicycle blindfolded on a tight rope while juggling chainsaws and feathers... You probably couldn't come up with a harder combination to try and start out with. Figure at least 1000 hours of good solid practice minimum with instruction, if not more. Most of the students I work with I'd bet that number would be almost double that.By the time you add up the machine, the electric, gas, rod and all the practice material, I bet you'd find the premade stuff "dirt cheap" in comparison. If you are doing it DIY without instruction, take that figure for practice and at least triple it.
Reply:I won't be one to knock increasing ones knowledge. I try to make a point of taking at least one class every year whether it's work related or just something on one of my hobbies.Your post however read like many typical new alum tig threads. Someone comes on, wants to buy an AC/DC tig ( I'll give you points for at least not picking a cheap one to start with) never having done tig, and wanting information on a complex project vs wanting to learn the basics. Start out learning to weld flat plate. When you can do decent joints on flat plate in all positions on say 1/8", then transition to thin material and do them all over again. Once you get those done, then move on to simple single tube joints and after being able to do all positions there, then transition to complex tube joints with restricted access.If you really are serious about doing this right, then you probably should be looking into some training. A class will get you farther for less money, then trying to blindly do it on your own. There are just some things that really can't be conveyed in videos or still picts on the internet. Even then, some people just don't "get" it..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:I got the best teacher today!Turns out i live literally one block away from the person who fabricates for Tomcat truss in Mexico.... and accepted  me as a trainee ...... they have a substation 440Volt service in the shop... and various stations to work with....The have a nice MIller Dynasty 300 brand new ... ufffff so jealous...Ill keep you guys updated.... I guess i just need the moral support around here!  So happy these guys are around my block....
Reply:Hmmmmmmmmm.......Hey Lynda where's that 12 pack of beer?  Miller Dynasty 350Twenty Six HammersThree Crow BarsBig Rock