Welding forklift forks

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My maintenance crew wants to take some forks off of a lift that had an engine blow up and use them on a similar sized capacity forklift. However, the mounting is different. Thus, they want to remove the existing clip type mount and weld tubing to the top to enable mounting on the other lift. My questions are:1. What are the ramifications of welding and/or tempering the forks by welding on the top where it mounts to the vertical risers?2. After welding, what should be done to temper the welds?A quick search revealed this information:1. Preheat to 600*F with a soft flame.2. Postheat to 800-850*F with a soft flame.3. Cool slowly.4. NEVER weld on the face, or under any circumstance the INSIDE RADIUS of the HEEL.5. Normally, never weld within half the diameter of the face. IE, 2" thick forks can only have a 1" weld on the sides.6. Anything else causes soft spots and weakens the forks from their load rating.7. Always match the lesser steel, usually mild steel, and use a low-hy electrode such as 7018 or 71T-1.This a condensed, generalized weld procedure from many fork manufacturers.Is this a fairly accurate procedure?Thanks!
Reply:the yale man told me to never ever under any circumstances weld the forks or the carriage (cast) of a forklift....they have always cracked any ive ever seen done..none by me..broke the cyl mtg lugs off for the tilt...they cracked.
Reply:where I work our original forklift the forks were in a bad position so they were cut off & rewelded together so idiots would not flip the forklift & pallets inside a store. it was a walk  type non powered with stationary post it just raised & lowered, they never cracked, nor had any problems, but I didnt see them get welded, & they were like that for 15 or so years. another store closed around 5 years ago & we got a powered forklift, it sure beats pulling that thing by hand.if it was still around I would take pics, but the forks were sliced off & moved about the width of the fork itself.  originally the foks were too close, & some pallets were very wide in middle runner & people couldnt get it but cockeyed under & would flip forklift with akward pallets or being top heavy, so solution was to move them outboard a few inches & never flipped again. our newer forklift the forks are adjustable inward & outward, but our oldone it was set up for narrow center pallets. RandyLast edited by knucklepanshovel; 08-12-2010 at 12:13 PM.Miller 140Campbell Hausfield migVictor torch outfitBlue Point torch setSmith torch with vintage Airco regulatorsVictor type A torch setHobart pipelinerLincoln Ranger 9Lincoln 225 tombstone
Reply:Originally Posted by BMLMy maintenance crew wants to take some forks off of a lift that had an engine blow up and use them on a similar sized capacity forklift. However, the mounting is different. Thus, they want to remove the existing clip type mount and weld tubing to the top to enable mounting on the other lift. My questions are:1. What are the ramifications of welding and/or tempering the forks by welding on the top where it mounts to the vertical risers?2. After welding, what should be done to temper the welds?A quick search revealed this information:1. Preheat to 600*F with a soft flame.2. Postheat to 800-850*F with a soft flame.3. Cool slowly.4. NEVER weld on the face, or under any circumstance the INSIDE RADIUS of the HEEL.5. Normally, never weld within half the diameter of the face. IE, 2" thick forks can only have a 1" weld on the sides.6. Anything else causes soft spots and weakens the forks from their load rating.7. Always match the lesser steel, usually mild steel, and use a low-hy electrode such as 7018 or 71T-1.This a condensed, generalized weld procedure from many fork manufacturers.Is this a fairly accurate procedure?Thanks!
Reply:+1 to the above, and I'll add "use stringers", multipass, no weaving, no cover pass. If a bead is more than 3x rod diameter it's time to kick butt.Matt
Reply:I had to do that job once. I used some heavy duty stuff for the eyes that were machined on the lathe and a heavy shaft for the forks to slide back and forth on. Your procedure there sounds good. I used 1/8 7018 until i could get decent build up with 5/32. soon as i could get the 3/16 rod in there with good fusion i blasted it away till the weld was complete. Also rotating and going back and forth so i didnt put too much heat into the metal and fast enough not to lose the preheat. still in service (when the mill is running) carrying full lifts of lumber bouncing away 3 years later.Nothing Ever Got Done By Quitting, Never Give Up.
Reply:Fork lift forks are forged steel that is bent on a mandrel.You can't weld them.I would compare it to the time that I worked at Miller Welding in Brookville PA and they tried to weld railroad wheels for freight cars.  The weld always broke on the tread.They had a wheel welder machine and tried all kinds of pre heat and post head and different wires and gases and nothing held up.The key is that the filler metal has to be as strong as the parent metal - but not stronger.Even when you get everything right, it usually cracks right beside the weld - if the weld holds in the first place.Fork Lift Forks are not expensive.  Tell them to buy some used ones and not be so cheap.The liability of someone getting hurt as a result of someone fabricating something is not worth the risk over a couple of dollars for some used ones.
Reply:When I got licenced as a forklift operator we were told any modification of the forks including welding, drilling, even burning a hole near the tip of the fork for a shackle to allow a choker to be attached, etc. would render the forks unfit for use and they would need to be replaced.
Reply:i worked for 8 years at a forklift engineering shop. you can weld fork tynes, we used to replace the hooks regularly, or move and re-weld them to suit a different sized carriage. we also welded clevices on them to take side shift cylinders, eyes on the top to mount them with pins, pad welded the bottoms to build up worn section, and heated and straightened them with a porta power if they were bent.same goes for the carriages, they can be welded no problem
Reply:I have had a pair of "universal" forks brought to me by a contractor. They had to have the top bracket welded on. I did them and they worked fine. They were for his Bobcat.I think I have seen these for sale in other places also.Miller Dynasty 700Miller 350P with Aluma-pro push-pullMiller 280 Dynasty with expansion card Dynasty 200 DXMigMax 215 Enuff power and hand tools to create one of anything..... but mass produce nothing!!!
Reply:I was told it could be done with MG600 rod. Ever bought MG600 lately? I can usually another used fork cheaper.Tough as nails and damn near as smart
Reply:Welding on forklift forks is a OSHA violation. The people involved with any such attempt would be liable for any consequences.6"XX P5P8 6G
Reply:Originally Posted by CofeWelding on forklift forks is a OSHA violation. The people involved with any such attempt would be liable for any consequences.
Reply:Originally Posted by tresiNot if done I/A/W munfactures proceedures. The lugs that engage the carrage are welded on and I have purchased them from a dealer. They may require that thier shop do the welding. However, you are correct if you're talking about repairing a broken fork.
Reply:Welding the forks can be accomplished but is not allowed at my shop because of insurance liability.
Reply:Originally Posted by Booger WelderFork lift forks are forged steel that is bent on a mandrel.You can't weld them.
Reply:Originally Posted by C6.7weldrigIm not saying that i recommed welding forklift forks... because i have seen how a lot of guys weld... but it can be done .
Reply:i am a pro and i still don't feel comfortable to weld on forks.    Even though AWS 15 different forms of faith my various welds.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:I agree with your opinion on this issue. This information is really fantastic and useful. Keep sharing more.Link removed by ModeratorLast edited by SWells; 10-28-2013 at 08:49 AM.
Reply:I have welded on a few heel clips but never a cracked or broken fork.  Some time in the manufacture of forks the mounting points are welded on.  I would follow the welding procedure set out by the manufacture.  People who just come out and say it is a osha violation need to provide documentation to back up their statement.  I like it when know it all's at work say something is an osha violation and it makes then mad when I ask them to prove it and they can't.Dan D.
Reply:In my experience in dealing with OSHA inspectors, they are just like cops. They don't want to get out of their cars, unless they have an agenda / report / issue / failure / or just plain got up on the wrong side of the bed! If there is an issue / failure with a repaired fork they're gonna want to see documentation from the manufacture! Letter of approval, and procedure for the repair. I would think that is going to be an up hill battle to get a forklift manufacture to give you a written repair procedure. They'll want to sell you a new fork.I remember in the 1980s OSHA really cracked down on holes being drilled or burned in the tips of forks. They would red tag a forklift immediately!https://www.osha.gov/SLTC/etools/pit...rts/forks.htmlDon’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:You do not weld or cut on forks..big time liability..tackleexperts.comwww.necessityjigs.comhttps://www.facebook.com/groups/mach...dingequipment/
Reply:Buddy of mine busted a fork, I told him I would weld it back up. I bevel both sides, lined it all up on my table, tacked it to table, tacked fork together, then cut loose, then welded with 232 innershield, .072. Then I made couple of flat bar to go on heel and welded them on. No problems so farSent from my SCH-i705 using Tapatalk
Reply:I welded a broken fork for a 966 CAT loader one time. The break was right in the heel. About 8-inches wide and 3-inches thick. I used 110-18, and standard weld procedure for T-1. 450-degree preheat, and interpass temp. Then wrapped the fork with insulation for a slow cool down over night. I watched that fork being abused for a couple years.Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:I just recently had to become certified in forklifts. From what I picked up is that Forklift forks under no circumstance are to welded or modified. Any modification to the carriage or other structural and mechanical parts must be approved by the manufacture and done by a trained professional. Load ratings must be re tagged accordingly. That's pretty much what I can remember of what OSHA sais. Its one of those things you just should spend the money to replace the forks, there are relatively cheap.PROUD   AMERICANOSHA stated:" 29 CFR 1910.178(a)(4) requires that 'Modifications and additions which affect the capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly.' In the event that a powered industrial truck manufacturer has been sold to another company and is no longer in business, the user or customer must contact the purchasing company to request approval. In the event that the original powered industrial truck manufacturer is no longer in business and has not been purchased by another entity, the user or customer would be required to contact a Qualified Registered Professional Engineer for approval of such modifications and additions."
Reply:Originally Posted by Booger WelderFork lift forks are forged steel that is bent on a mandrel.You can't weld them.I would compare it to the time that I worked at Miller Welding in Brookville PA and they tried to weld railroad wheels for freight cars.  The weld always broke on the tread.They had a wheel welder machine and tried all kinds of pre heat and post head and different wires and gases and nothing held up.The key is that the filler metal has to be as strong as the parent metal - but not stronger.Even when you get everything right, it usually cracks right beside the weld - if the weld holds in the first place.Fork Lift Forks are not expensive.  Tell them to buy some used ones and not be so cheap.The liability of someone getting hurt as a result of someone fabricating something is not worth the risk over a couple of dollars for some used ones.