Hitch with pulsed spray

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Here is another job I got in.  The hitch was bolted to the expanded metal step bumper.  BIG bolts, but still only expanded metal.  The mount to the truck was 2x2 square tubing, maybe 1/8 wall.  It rusted off.  They asked me to fix it.  I told them I would have to scrap the original step mounts and start over.  They said fine.  This truck has no plug for lights and no brake controller.  Its supposed to be for light duty towing  I had some used 2 x 3 x 1/4" angle.  I cut 2 pieces 25" long and welded them to the frame with 15" hanging out.  After I did that, I noticed they were not even.  I dropped a plumb from the body and had to cut 1/2" off the left side because the frame was not cut off even in the first place.  Original hitchOriginal mount.......Angle welded to the frameMachine.  The settings varied from 150 ipm (SPD) to the 290 (HOT) you see here.035 wire, 92% argon, 8% Co2over and up, 200 ipmReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Here are the dimes some folks like to see.  I don't need them, so the rest is just welded.  I think just a nice smooth bead looks good.Over head butt small gap, no bevel.  1/4" to 1/4"Frame and mount.  On the left you can see the old mount.  You can also see I had enough heat when I welded the angle to the inside of the frame by looking at the outside.I was going to notch the second (front) crosspiece like I did the rear, but I put it in the saw and took a few pictures.  Next thing I knew, the saw stopped and I cut right through it instead of stopping it.  SO I cut it to fit in the center.  I didn't have any more angle to do it again.  OOps...Done.  I sprayed the whole thing with rubberized undercoating before attaching the step.The mess to clean upTotal time including clean up 4.0 hours.  92 lbs of used angle.Last edited by David R; 10-02-2008 at 09:35 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Once again very nice work david!!!Ya gotta spend money to make money!
Reply:Nice job Dave. Keep up the great work and posts.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Sheesh, that original trailer hitch was bolted to expanded metal?!?!?!That's just wrong.Glad you came up with something more solid to mount to.No brake controller I can understand for "light duty trailers".But AFAIK, every trailer has to have some sort of lighting.  Bigger trailers are required to have more marker and running lights, but even the smallest trailer is required to have brake and turn lights.Still playing with the pulsed MIG, eh?  And does the loading ramp clear the step platform?btw, nice job.    The best laid schemes ... Gang oft agley ...
Reply:In this state a single purpose trailer like the log splitter, welders, cement mixers,and air compressors don't need lights if you can see the lights on the truck.  They don't even need license.  If you put a tool box on the trailer or anything else, the law changes.I love the pulsed spray, but still getting the hang of it.  It has a LOT more heat than mig.  Nice fluid controllable puddle.  I never checked the loading ramp  .  The step is one or two inches higher than it was.  It also used to be a little tilted down in the back.....  The truck is still in my shop, I will check today.  Thanks.If you look at post 1 pic #2, you can see one of the 5/16" carriage (read butter bolts or grade 2) bolts that holds the expanded metal to the original mount.  These bolts were almost rusted in two.   I'll try for a pic of the bolts today.  The bolts that held the hitch on were (2) 5/8' and (2) 1/2" through the expanded metal.Its a single wheel F350.  The unicel body is heavy, the rear tires (10 ply) are squished with the truck empty and 80 PSI in them.  I hope they don't put too much weight on them.Light duty.  That is a 2 5/16" ball on there.....DavidLast edited by David R; 10-03-2008 at 05:53 AM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:you seem to be pretty talented there david i admire your work.
Reply:The ramp works fine.Thanks to everyone for the comments and complimentsPulsed spray all the way!David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I like the overhead 1/4" weld you made.  I know Ive read probably 100 times on what kind of Lincoln unit that is, but can you refresh my memory.  Nice repair weld it like you own it
Reply:Lewray, its a Lincoln V350 Pro.  425 amps @ 60%,  100% duty cycle @ 300 amps. CV (mig) up to 45 volts.  I bought it 2 years ago and bought the advanced panel last december.   Once I  had it up to 400 amps running dualshield.   EeeeHhaaa!Smoooth stick and mig welding, Gouges like crazy.  Simple (like me) to operate.Pulsed spray likes CLEAN steel.  If I run into any crud, it makes a mess.With .045 wire on 3/4" plate in pulsed spray, the arc is below the surface of the plate.  Almost all the time I use .030 or .035.David Last edited by David R; 10-03-2008 at 08:54 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RLewray, its a Lincoln V350 Pro.  425 amps @ 60%,  100% duty cycle @ 300 amps. CV (mig) up to 45 volts.  I bought it 2 years ago and bought the advanced panel last december.   Once I  had it up to 400 amps running dualshield.   EeeeHhaaa!Smoooth stick and mig welding, Gouges like crazy.  Simple (like me) to operate.Pulsed spray likes CLEAN steel.  If I run into any crud, it makes a mess.With .045 wire on 3/4" plate in pulsed spray, the arc is below the surface of the plate.  Almost all the time I use .030 or .035.David
Reply:Another potential disaster averted!  I like your posts.  Nice job.Never seen a 2-5/16" ball on a those Home Depot log splitters?MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:I'm waiting for someone to bash you about trailer hitches needing to be bolted on. heheheOh, sorry, is that stirring the pot?Cool fix!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:looks nice david, that vert up is slightly crowned as i'm sure you are well aware of. i'm sure it's fine for the intended application. good job as usual. --Gol'
Reply:Originally Posted by Go1lumlooks nice david, that vert up is slightly crowned as i'm sure you are well aware of. i'm sure it's fine for the intended application. good job as usual.
Reply:I just read on lincoln's website that you can parallel that bad boy and get 700amps for gouging!!! Holy Cow! That's a grip of cash if you want to do that!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:Originally Posted by Joker11I just read on lincoln's website that you can parallel that bad boy and get 700amps for gouging!!! Holy Cow! That's a grip of cash if you want to do that!
Reply:Originally Posted by HARRY BARKERslightly crowned? is it not supposed to be?sorry i'm lost here.
Reply:Originally Posted by Go1lumlooks nice david, that vert up is slightly crowned as i'm sure you are well aware of. i'm sure it's fine for the intended application. good job as usual.
Reply:nice welds davidLincoln 255XT Power Mig                                                                    Lincoln Precision Tig 225Hypertherm Powermax 30
Reply:Originally Posted by rwells173nice welds david
Reply:Originally Posted by HARRY BARKERlooks fine.im gonna have to search this other guys(textbook) posts.ha.hahaha.
Reply:Originally Posted by rwells173huh???????
Reply:looks like you vastly improoved that hitch.a question for you DavidRDo you use pulsed all the time with mig?just askin' as i dont mig that much, and havnt even got pulse. in fact i would probably burnt 7018 on that if i could have got it clean enough.....but i'm not knocking your method, just asking as i know you use 7018 and other methods also, so do you think mig pulsed is better or has an advantage?dont mind getting pulse if it advantage. What do you think?G
Reply:Mig is faster. Pulsed spray for good penetration and control of heat.http://content.lincolnelectric.com/p...ture/nx270.pdfhttp://www.millerwelds.com/education...rticles20.htmlCity of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDannyYou have to use it to appreciate it.  When I bought it, I didn't know what I was getting into.  The puddle is more fluid which I like.  The heat is more controllable.  I have more reasons.  Pulsed spray is a completely different process than Mig.  No slag, great out of position or flat. Great penetration and wetting out of the bead.No, I do not use it ALL the time, but it makes jobs easier.  Stick, cored wire, PULSED SPRAY METAL CORE, mig tig........ What ever process is best for the job.Come on over to my shop and try it.  This invitation is for everyone.David  Originally Posted by gordfraserlooks like you vastly improoved that hitch.a question for you DavidRDo you use pulsed all the time with mig?just askin' as i dont mig that much, and havnt even got pulse. in fact i would probably burnt 7018 on that if i could have got it clean enough.....but i'm not knocking your method, just asking as i know you use 7018 and other methods also, so do you think mig pulsed is better or has an advantage?dont mind getting pulse if it advantage. What do you think?
Reply:thanks for the info and the invite, but thats a good days drive from here. next time i'm out that way....Can i ask another way?When you are using mig how much of the time do use pulsed mig?Seems to me that the benifits would make it usefull most of the time miggin.G
Reply:I almost never use mig.   Exhaust jobs, I use an SP100.  Pulsed spray is too hot for that thin of steel.  I do some small production jobs, most of them are piece work and the pulsed spray saves me time.   One of the jobs is an oil cooler that has to be air tight, pressure tested at 80 psi.  I have tried Mig and got too many leaks.  Pulsed spray is faster, easier, looks better and has less leaks with little or no spatter if I do my part.  The plate on those is too thin for true spray.   Like any other process, the heat has to be right, but its easy to set.Right now I am setting up another welder with Mig, tig or stick on a cart.  This is for other jobs that come in the shop, or working on stuff outside my shop in the driveway.Once you have used it, Mig seems a little too cold and archaic. So to answer your question I guess 99% of the time if the process fits the job.David Last edited by David R; 02-22-2009 at 10:55 AM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Dont want to hijack but I see you use .035 metal core wire. Can you tell me what you use it for mainly?
Reply:Originally Posted by lars66Dont want to hijack but I see you use .035 metal core wire. Can you tell me what you use it for mainly?
Reply:Nice work.I would like to see some kind of "X" in the hitch to prevent lateral twisting. I can see some one overloading a trailer, and have that fold your hitch like an accordion.
Reply:Originally Posted by Fat BastardNice work.I would like to see some kind of "X" in the hitch to prevent lateral twisting. I can see some one overloading a trailer, and have that fold your hitch like an accordion.
Reply:And with a 2 5/16 ball, you are gonna believe them?X or Y brace it to save on insurance costs.......(and yer azz)MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Wow. looked at pulsed mig options and once i found i couldnt put an optima on my TB302 for @1K it got real expensive.Like 3.5K and up depending on how portable you want.MMMMmmmG
Reply:So far as I know, an Optima will only directly hook up to an XMT or a Pipe Pro.   You'd have to run an XMT off your Trailbalzer to use an Optima.   An XMT 304 cc/cv + an Optima is about the same money as an XMT 350 MPa, which already has the pulse built in.MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Nice work on the hitch David (as always).  MM350P/Python/Q300MM175/Q300DialarcHFHTP MIG200PowCon300SMHypertherm380ThermalArc185Purox oaF350CrewCab4x4LoadNGo utilitybedBobcat250XMT304/Optima/SpoolmaticSuitcase12RC/Q300Suitcase8RC/Q400Passport/Q300Smith op
Reply:Originally Posted by gordfraserWow. looked at pulsed mig options and once i found i couldnt put an optima on my TB302 for @1K it got real expensive.Like 3.5K and up depending on how portable you want.MMMMmmm