1/8" steel fabrication question

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I need to make a shelf to place my disc sander on.  The stock sander shelf was 1/8" steel and was like an open box with the edges folded up.  As a result the edge of the shelf has a nice curve.I do not own a metal brake, so I bought some 1/8" steel plate and 1/8" x 1.5" steel strapping.  What I am going to do is weld the 1.5" steel strapping to the edge of the plate to make the shelf.  What process will give me the roundest finished edge?  I have a 240v MIG, oxy/fuel torch, and a stick welder.My first inclination was to use the torch and fusion weld the joint and sand it smooth, but now I am thinking the MIG welder from the top side may be the better bet.Suggestions?Here is the disc sander in question.Chris
Reply:Here is a picture of what I am trying to weld
Reply:Suggestion and ?Are you better at MIG or Oxy Acety? Fussion should work fine for this. Leave the outside corner lapped @ 1/16" or a little less if you can. Clean it and go. No need to use up the MIG wire.If you have extra 1/8" material try both. If I MIGed it I would tack the outside so you had a nice V to fill in and weld vertical down and go to town. Attached Images
Reply:I'd use the mig followed by a sanding pad. Built tons of stuff from belt guards for pumping units to catch pans to water and fuel tanks that needed a nice smooth rounded edge that way. Tack it up and leave yourself a nice notch to weld in so you don't take off all of your filler. Mig wire and electricity are cheaper than oxygen and acetylene.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Fusion and be done, watch it flow like butter.  I am not as good as other with MIG.Setup like Waldarosa stated for fusion.  The 1/16" set back is very important if you are going to sand.
Reply:mig no questionBest way to round the corners is get a 60 grit flap wheel and hold it flat on the joint and go to town, take long passes and it will come out near perfect after some pratice.Have we all gone mad?
Reply:Alright, first thing was to do a test weld:Good penetration as far as I can tell.  I am really starting to like my new 240v MiG welder.  The welder was dispensing a lot of wire, so I finally decided to turn down the wire feed a little bit.  I am going to have a lot of grinding to do tomorrow.  I also learned the great importance of proper fitting, the first shelf was a little sloppy and the welds did not come out as well.  I guess I was getting globular transfer as the welder was going pop pop pop as I was welding.  When I had to weld a butt joint the arc went completely silent, what does that mean?  Thanks for the advice I will post pictures after sanding is complete.  BTW I used 0.025" L-56 wire and my 91% argon, 5% oxy, 4% co2 shielding gas.
Reply:Originally Posted by *chris*...I guess I was getting globular transfer as the welder was going pop pop pop as I was welding.  When I had to weld a butt joint the arc went completely silent, what does that mean?...
Reply:Tim often that pop pop pop sound means your wire feed is to fast in short arc. The wire is hitting the steel some times rather than melting. Next time you have that happen take a close look at the wire and the puddle as you weld. Then turn down the wire speed a bit and see if it stops.
Reply:OK, thanks, I'll try that.
Reply:I will get that pop, pop, fizzle crap when why wire is binding up in the gun/liner. Then I will take notice that I have a pretty severe bend in my gun/cable. Straighten everything out and I am cooking again, provided my settings are correct. Just something to consider, keep your gun/cable as straight as possible.....BrentLincoln 3200HD MIGLincoln AC/DC 225 Stick
Reply:Originally Posted by Brent13I will get that pop, pop, fizzle crap when why wire is binding up in the gun/liner. Then I will take notice that I have a pretty severe bend in my gun/cable. Straighten everything out and I am cooking again, provided my settings are correct. Just something to consider, keep your gun/cable as straight as possible.....Brent
Reply:Looks real good and should smooth right out with a tiger paw or other flap disk. Try turning your wire speed down just a touch more on a corner joint like that, and never be afraid to make small adjustments and experiment a little. Changing positions will usually require a minor wire speed adjustment.The difference between art and craft is the quality of the workmanship. I am an artist.
Reply:Alright, complete!  I went through a half dozen 36 grit sanding discs, but I am happy with the results.I found the 36 grit sanding discs were more aggressive than a 24 grit grinding wheel that I bought at AIrgas.  What is the most aggressive cutting tool for a small angle grinder?Here is the complete machine, a WWII era Delta 12" disc sander.
Reply:That came out really nice!
Reply:looks good
Reply:Chris the most aggresive would have to be a grinding wheel not to be a smart a$$. Some cut faster than others I have noticed. I have 2 cases of 4 1/2" wheels for SS that I got for a bargain so thats mostly what I have been using for general heavy work.The stand looks great. If I didn't know better I'd say it was store bought.
Reply:Originally Posted by DSWChris the most aggresive would have to be a grinding wheel not to be a smart a$$. The stand looks great. If I didn't know better I'd say it was store bought.
Reply:Turned out real nice.
Reply:Nice job. Looks like it was bent in a press brake...BobBob WrightSalem, Ohio  Birthplace of the Silver & Deming Drillhttp://groups.yahoo.com/group/southbend10k/http://groups.yahoo.com/group/sawking/1999 Miller MM185 w/ Miller 185 Spoolmate spoolgun
Reply:Ya hate to get that dirty it came out so good.pro-level dumpster diver                                     Hobart 125EZ
Reply:Very nice.
Reply:Originally Posted by stevinatorYa hate to get that dirty it came out so good.
Reply:It is a really nice job.For the grinding wheel.  A grinder will take off more steel than a sanding disk.  The grinding wheel lasts longer and you can lean on it.David Real world weldin.  When I grow up I want to be a tig weldor.