Little repair job I did...

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Heres a little repair job i did, the customers railing got hit by a tree in the storm, was pretty mangled up... This is what the railing looks like, only the 2 pickets on the outside actually go through the channel in the middle, the 2 in the middle, are added on pieces i think,  http://www.philswelding.com
Reply:so anyway, i start cutting the pieces to fabricate this little panel, and i realize that the channel that was used on the railing, is 4-1/4" on center punched holes, and the stuff i buy from kings metals, is 4" on center punched holes.. so i had myself a little dilemma.  I dont like to use regular channel ad just weld the pickets to the channel becuase 1, its a lot more work, having to shim and space every picket, and more importantly, 2, it looks nowhere as good as when the pickets go through the punched channel and are welded from the bottom.  i couldnt use my channel cuz in 45-1/2" there would have been an extra spindle and then the spacing wouldnt have worked with the picket layout.   so i just used regular channel, and ground a little bevel on the bottom of each picket, and ran a really small bead, and then just added pieces to the topp and bottom to make it look like it went through the channel... http://www.philswelding.com
Reply:It didnt look too bad once i grouund it down a little, And then i just welded the top channel on, with the cap rail:It came out pretty good i guess, http://www.philswelding.com
Reply:The install went really well, I think it took me less than an hour to install it:so thats it, it blended in perfectly with the railing, and the customer was really happy with it. http://www.philswelding.com
Reply:looks nice!Couldnt have done it better myself.
Reply:Nice job.Trailblazer 302Hobart Stickmate AC/DCLincoln SP 135 TSmith torchSpoolmatic 30A
Reply:Looks good. Repair blends excellently.  Looks heeeaaavvvy.   Snow, wowTorch or plasma cut holes work.  I have made templates in the past.    Probably no time saving for one panel.
Reply:Nice.Jobs like that feel rewarding to me.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:I see I'm not the only one who uses those orange woodworkers clamps for steel. Nice job. I'm getting some work from the storm, but not as much as I'd have liked to..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:yup, we got 3-4 inches in that last little storm,DSW, i love using those orange clamps, theyre a lot cheaper than welding clamps, and theyre plenty strong enough for doing railings/fencingTapwelder, you use a plasma for cutting holes in the channel? ive never thought of that before, do you have to clean up the holes with a file when your done? http://www.philswelding.com
Reply:I have used a o/f torch.  Not much cleanup with a template and good adjustment.   Not something I would depend on and only did if for bars and gates several years ago.   I punch my stuff now.  If you ever have to extend through channel,  weld around and then grind.  Round holes work  well.  The weld lays flatter than butting or tight square holes and much less clean up.
Reply:Originally Posted by tapwelderI have used a o/f torch.  Not much cleanup with a template and good adjustment.   Not something I would depend on and only did if for bars and gates several years ago.   I punch my stuff now.  If you ever have to extend through channel,  weld around and then grind.  Round holes work  well.  The weld lays flatter than butting or tight square holes and much less clean up.
Reply:I used to have a small 20ton roper whitney c- punch. I made a die.  http://weldingweb.com/vbb/showthread.php...+roper+whitney  The round holes works well because you picket will be centered, too. Not suggesting this method is better than a close fitting square hole that doesn't have be welded-up.  Though it will work for getting you out of a bind.
Reply:I'll keep it in mind, thanks tapwelder,  It would've been helpful on this job. http://www.philswelding.com