Advice wanted for installing 6’ high iron fencing

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My boss asked me if I want to install a 6ft high x 1600 ft iron fence and I want to do it because it will be a change and sounds like fun. I will be doing it by myself and will have to dig all the post holes and set them in concrete myself. I have installed the cheap 3’ high fencing from Home Depot at my house, but never fencing of this size. It probably will not be for a couple of months and there is no rush. The place has a 6’ high chain link fence now, but the copper thieves keep cutting through it, so we are going to repair the chain link and add the iron fence on the inside with razor concertina wire lying on the ground between the two fences. I only have a small Lincoln 120V MIG welder and I think it should be ok although I may be able to bring my personal Lincoln 220 arc welder although I don’t really want to because I’ll need a 200 ft power cord which I don’t have. I could rent something but then the pressure will be on to get it done and I definitely don’t want that.Anyway is there anything I should be aware of before I agree to this?
Reply:This is more than a one man job, How many post holes will need to be dug in what kind of soil?Who will be digging them?How will the panels be attached to what kind of poles?Will you be welding the panels directly to the fence posts or will there be brackets used.Will you be expected to fabricate the fence panels?If you take on the job, your boss can expect to save on the cost of a fencing contractor doing it.  Out of the savings , or in lieu of rent for the use of your welder, the boss could charge an appropriate extension cord to the cost of the job.If only for reference purposs, your boss should get an estimate or proposal from a fence contractor so that there will be a realistic basis for what the job will be worth. This is something to be approached with great caution. One of you might get the impression that someone is taking advantage of another.GailI 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:Are you building it all onsite? I can't Imagine how that's a one person job.
Reply:I built this onsite with a lincoln 140 mig,,,,,,,but I had a few helpersI set up a 10 x 20 car port type tent,made all the piece's,primed and painted the first coat,It's do able but get a few helpers
Reply:I don't know what just the install would run, but 7 or 8 years ago dad had an iron fence installed across the front of his back yard at the cost of $40/ft plus gates, plus caps, plus hardware.... I don't know what the installation runs on something like that, but with 1600' of it, part of the budget should be able to cover the proper tools to do the installation. That's roughly 200 holes to dig, 200 poles to set, couple hundred bags of concrete to mix, 200 panels to fit and install along with all the other stuff that I'm probably leaving out. If it's a fabrication job as well, you're talking about a very large undertaking. If you plan on going at this with an extention cord and a hobby welder, clamshell digger and a wheel barrow, you'll end up breaking your back and the bank at the same time. Just think of the time it would take to do one post. If you are not going to have anyone to help you, you'll need to utilize equipment. Go to the rental yard and rent a wheeled power auger for 3 days and knock your holes out. Place all your posts and then go back and rent a powered concrete mixer and set your posts. After that, I'd look at renting some welding equipment like a gas powered welder that you can run a suitcase off of and some flux core. Something like a drywall lift or modified drywall lift would probably be very helpfull in getting the panels into position. Doesn't sound like a one man job to me. I imagine that with one man working on it, it'll end up being a 2 month long kick in the nuts. But if they're willing to pay for it and have a timeline based in reality AND are willing to pay you to do such a job without having to kill yourself in the process, a change of scenery is always nice and could be fun to do.Good luckPowcon 400SM2-PD60 wire feedersMiller XR controlAlumapro push/pull gunSpeedglas 9100xBFH
Reply:Originally Posted by Bryan27 That's roughly 200 holes to dig, 200 poles to set, couple hundred bags of concrete to mix, 200 panels to fit and install along with all the other stuff that I'm probably leaving out. If it's a fabrication job as well, you're talking about a very large undertaking. If you plan on going at this with an extention cord and a hobby welder, clamshell digger and a wheel barrow, you'll end up breaking your back and the bank at the same time. Just think of the time it would take to do one post. If you are not going to have anyone to help you, you'll need to utilize equipment. Go to the rental yard and rent a wheeled power auger for 3 days and knock your holes out. Place all your posts and then go back and rent a powered concrete mixer and set your posts. After that, I'd look at renting some welding equipment like a gas powered welder that you can run a suitcase off of and some flux core. Something like a drywall lift or modified drywall lift would probably be very helpfull in getting the panels into position.
Reply:Thanks for all the replies and sorry I couldn’t get back right away, but I was working where internet wasn’t available. Wow, there sure is a lot to think about and there is a lot of stuff here that did not occur to me. Anyway since there are so many replies I’ll try to cover it all in one post.This fence is at a remote site and the only fence contractors willing to do it want over $100K and that’s how I got involved. I have experience with installing chain link fencing and I once worked a couple of months installing miles of deer fencing around a vineyard, but I did have a helper and a small tractor with an auger. It was a long time ago and I still remember who much I enjoyed it The soil is sandy with some rock on top and should be easy to dig by hand. If I use an auger then I do have help available and will use them for digging the holes, but they are electronic geeks and I would rather not work with them if I can help it. They are not skilled in simple manual labor tasks and they drive me nuts with their complaining. As for the concrete, I’m ok with mixing it myself I as long as I can do it at my own pace. If I get a truck delivery then all the posts has to be done within a few hours and I’m defiantly not up to that and the geeks aren’t going to be able to do it on their own. So that means I’m going to be running my butt off setting all those posts. They are still getting prices on premade panels and are talking 8’ high instead of 6’. Two sides will have to custom made for a slope. I wasn’t really thinking about the weight of them until now. I have a Harbor Freight Pickup Truck Crane mounted on my truck and was planning to use it to pick up the panels and hold them in place. I’ll wield the panels to the posts, but now I’m having second thoughts because of the panel size and weight. I don’t know if they are going to be 8’ or 10’ long. I don’t know what the cost of the prefab panels is, but if its half of the $100k quoted then they can afford me doing this for a month or so. Of course after all the numbers get in for the actual cost and it’s a big savings, I may be trapped into this with no way out except to retire early. PHOTO OF NEW FENCE LOCATION. 2FT INSIDE CHAIN LINK.
Reply:Originally Posted by sleeperMy boss asked me if I want to install a 6ft high x 1600 ft iron fence and I want to do it because it will be a change and sounds like fun. I will be doing it by myself and will have to dig all the post holes and set them in concrete myself. I only have a small Lincoln 120V MIG welder and I think it should be ok although I may be able to bring my personal Lincoln 220 arc welder although I don’t really want to because I’ll need a 200 ft power cord which I don’t have. I could rent something but then the pressure will be on to get it done and I definitely don’t want that.Anyway is there anything I should be aware of before I agree to this?
Reply:THIS has all the makings of a major CLUSTER FULK.Syncro 250 DX Dynasty 200 DXMM 251 w/30A SG XMT 304 w/714 Feeder & Optima PulserHH187Dialarc 250 AC/DCHypertherm PM 1250Smith, Harris, Victor O/ASmith and Thermco Gas MixersAccess to a full fab shop with CNC Plasma, Water Jet, etc.
Reply:Originally Posted by dave powelsonIf you're never dealt with voltage drop, it sounds like you're going to:200' extension cord for 120 V is hopeless8/3 or 8/4 cable extension for Lincoln 220 welder....may be pushing it,I think it would need to be 6/3 or 6/4 cable.......which is significant enoughbux, weight and hassle to justify using a welder suitable to the task;even if your boss doesn't understand.
Reply:If a 12 guage extension cord is good for 100', then I am absolutly certain that a 10 guage cord will serve for 200'.the longest extension cord I have used was 250' of 12 guage, back in 1971.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:Originally Posted by nadogailIf a 12 guage extension cord is good for 100', then I am absolutly certain that a 10 guage cord will serve for 200'.the longest extension cord I have used was 250' of 12 guage, back in 1971.
Reply:Originally Posted by sleeper  Oh well, only three more years to retirement.
Reply:Originally Posted by sleeperWell this was really what I was thinking about when I started this thread. I am not worried about the regular construction stuff because I’ve been working construction all my life and that’s not a problem for me.I have used this welder on a 100ft 12 AWG cord without much of a problem, but not with a 200 ft cord. I’m more worried about welding up these panels with this little wire welder not counting the cord. I’m starting to realize how heavy these prefab panels are going to be and with only 4 points to hold it all together, I’m a little concerned if my welds are going to be good enough.  Anyway I’m about to tell the boss that I can’t weld them with this welder plus it’s to far to drag a cord big enough for a big welder and he will need someone with a truck mounted welder. I really would like to do it, but this maybe over my head for one person and I can not work with those other clowns. I’ll have to see what happens, he just might tell me to do it anyway and I will not have any choice. I may have to rent a welder or maybe a generator. Oh well, only three more years to retirement.
Reply:Originally Posted by shovelonMight be a candidate for the battery powered mig. Charges on 115volt, welds like 220 volt mig.Where in SoCal are you? I am in the San Fernando Valley.
Reply:The Hobart battery powered welder won't last you.http://www.hobartwelders.com/product...wered/trek180/For the amount of welding you need to do might as well just buy a 4-5k generator and some ear Plugs.hmmm Hi Desert, bunch of geeks  , electrical stuff  what you got going on out there?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 Broccoli1hmmm Hi Desert, bunch of geeks  , electrical stuff  what you got going on out there?
Reply:Just a simple question, you refer to this fence as "iron" is it steel. cast steel or "cast iron".
Reply:Originally Posted by weldbayJust a simple question, you refer to this fence as "iron" is it steel. cast steel or "cast iron".