Where did I screw up?

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This is a wire storage unit for a customer.  It holds 500 lb wood spools of wire.  Not all of them will be 500 lbs, some are much less, but the biggest one is that heavy.  They are as big as 32" around, so I couldn't fit many.  There will be a piece of 1.5" pipe going through them, uprights will be spaced 37" apart.  Its my design, I had not much to go by.  I started with the angle and thought if they bump a spool while loading another, it could fall off so I added 1/4 X 2" to the back, then I decided I better be over half the pipe in the front too, so a piece of 1/4 X 1" went on the front.  There are better ways to do this.  I piece of 1/4" X 2" bent in  a U would have been the way to go, but.....  Tubing is 2" with 3/16" wall.  Everything else is 1/4".  Top bolts to the ceiling joists, bottom is anchored to concrete.  Welder was set on 17.1 volts, .035 wire, 244 ipm.Raw materials.  I did NOT remove the mill scaleThis is how I set it up.  The magnet keeps the piece square and had no effect on the weld.First weldNext tack The gapReal world weldin.  When I grow up I want to be a tig weldor.
Reply:The gap filled in one pass.  I made a U shaped weave.The ends were welded flat.  I turned them 4 times.Finished productWhere did I screw up?David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:i give up were did you screw upChuckASME Pressure Vessel welder
Reply:Is this a trick question?  Maybe you didn't charge enough?  Welds look great.
Reply:Not a trick question. I was sitting having a cup of coffee and a smoke admiring my work and said OH Sh1t!Look again.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Tough to tell from the pics.I'll say either a dimension error or an orientation error.  Last pic, is the 'big' lip on the right-most column facing opposite from the other big-vs-little lips?
Reply:YOU GOT IT.  I made 2 lefts and no right.  Gotta fix that DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Or is it the top-vs-bottom plates?Or is it the big rectangular plate (the top plate to attach to the ceiling beam?) was supposed to go side-to-side instead of front-to-back?
Reply:i just figured thy were all left handed spoolsChuckASME Pressure Vessel welder
Reply:Good eye, moonrise.  David, like I said, maybe you didn't charge enough, you know, to cover the re-work part of the job.
Reply:Ooooo, I win!Plasma off the 'big' lip excess and make it a 'small' lip.  Take the off-cut and weld it to the 'small' lip and make it into a 'big lip'.  Flap-disc it smooth, paint it and it'll probably not even be noticed.
Reply:I took a sharpie and wrote FRONT and TOP on each one so I would get it right and still fugged up.Looks like a little more welding tomorrow.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I think you may have made the two outer posts identical, instead of a Left Hand and a Right Hand version. At least that's what it looks like to me as I sit with a coffee but no smoke."One of the things we have to be thankful for is that we don't get as much government as we pay for." (Charles Kettering)Mitch 180 (NZ)Lincoln SAM-400-220 + ?-400 Fordson Major + 2 x Tractapac Humber 80 + Procut 40 PlasmaMiller Spectrum 375
Reply:Originally Posted by David RI was sitting having a cup of coffee and a smoke............David
Reply:"The gap filled in one pass......"I didn't know you could do that much air.  I 'would have thought' to make that piece long enough to 'touch the edge'. Gotta love a wire feed. Again, thx for the pics of enlightenment.9-11-2001......We Will Never ForgetRetired desk jockey. Hobby weldor with a little training. Craftsman O/A---Flat, Vert, Ovhd, Horz. Miller Syncrowave 250
Reply:Originally Posted by Craig in Denver"The gap filled in one pass......"I didn't know you could do that much air.  I 'would have thought' to make that piece long enough to 'touch the edge'. Gotta love a wire feed. Again, thx for the pics of enlightenment.
Reply:Originally Posted by David RGood description:   getting air.   David
Reply:And here I thought you just missed the dime.Nice job accept for such an obvious screw up. My Photos on Flickr
Reply:you got hate that its easy to do but its only a f*uck up if you can't fix it  Last edited by wello; 06-17-2008 at 06:45 AM.Creative metal Creative metal Facebook
Reply:If your not screwing up once in a while your not doing enough.