Cable trailer build

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I have made a few of these.  An electrical contractor asked me about one.  I said sure.  The cable reels will not be over 42" or 1500 lbs each, so I am building him a trailer that will hold 2 48" reels @ 2,000 lbs each.  I am not an engeneer, so I just over build.  Material is 2 1/2" square tubing 1/4" wall.  About 300 lbs for 48'.  4 12' sections.  All welds are made in position, Pulsed Spray MIG first using .045 wire with 98 argon, 2% Oxygen.  later I switched to .035 wire and after that, 92 argon, 8% Co2.  I am still new with this process, so I keep experimenting.It all started here.  I bought the steel and another $300.00 of angle and flat stock on speculation.  Just to keep on hand.Laid out and square to 1/16"Tacked together with the SP100.  Nice tool for that part of the job.Vertical up inside the V of the 45* angle.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I got porosity when I ran over one of my tacks, so I ground off the weld and did it again.  More porosity, ground it off, did it again, same thing, so I said phuck it and got out some 3/32 7018 and made 2 passes @ 90 amps.  These 2 welds are the only 2 that I did with stick.A little closerHere is the profile Last edited by David R; 02-11-2008 at 08:21 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Back to pulsed spray.I wasn't satisfied with that joint, so I added 2 more gussets.  They aint gonna break this one!upright to hold the cable reel fillet.  Pulsed spray of course.  Still working on the craters.This is how I tied the ONLY cross member to the rest of it. All welds are 2 passes except the vertical up.  They are one.Each bead is 2 passes in deep.Last edited by David R; 02-11-2008 at 08:37 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Making more gussets.Date sez 199506.  One motor, countless blades, but its been a good saw for $179.00This is as far as I got this afternoon.   Unfortinatly,  a minivan came in on the hook with transmission problems came in tonight, so tomorrow I will be working on that.  I called to get a pintle height so I know where to put the spindles.   Another job of 18 pieces came in to weld.  Both jobs go ahead of this one.  More pics when I finish.You can see by the rust on the saw and the steel my roof leaks.  I will be moving to a bigger shop with no leaky roof and INDOOR plumbing in the next few months.  Boy will I be glad!Thanks for watching David Last edited by David R; 02-11-2008 at 08:30 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Overbuilding is always better than underbuilding.And Christ Dave, you look COLD!! It was pushing 11 degrees out my way by the shore today. Can't imagine what you guys were experiencing up there.
Reply:You make me laugh.  That isn't me, its the delivery guy for the steel.  It was 6 today and WINDY!  I stayed inside and keep the heat at 50.  Lots of layers.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:That delivery guy looks real happy that you decided to order an ***-load of steel in the middle of a 6 degree and windy day. Actually looks like he more or less dumped it off the side of his flatbed and then started coming after you.
Reply:Nice work David. The gussets are harcore.Miller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:Pretty cool project. Did you find the cause of the gunk in the welds?? Just a bad batch of dirt in the steel?? That sucks sometimes when that happens.And then, after so much work...... you have it in your hand, and you look over to your side...... and the runner has run off. Leaving you holding the prize, wondering when the runner will return.
Reply:Originally Posted by RojodiabloPretty cool project. Did you find the cause of the gunk in the welds?? Just a bad batch of dirt in the steel?? That sucks sometimes when that happens.
Reply:You wire brushed it, fine . Did you clean off (acetone or other solvent) the oil off that NEW steel.  Just wondering .[SIZE="5"Yardbird"
Reply:Thats not too cold up there, its been lingering about -10 here lately, with -40 windchill the other day. One of those days where you can throw boiling water in the air, and listen to the ice fall down on the ground.I like the idea for the gussetts, you can never have too much protection.  What will go as a surface material and axle?I'm 21 and learningAvid 4wd enthusiastASE Master tech (Automotive), mechanic/fabricator by trade
Reply:Our shop leaks all over the place! You have to know where not to park your tools! Still, everything gets wet. City 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 BibleDanny
Reply:I worked on it today.  I did all the under side welds overhead.  I didn't feel like turning it over, so on the floor I went.  Here are some pics of pulsed spray overhead.And a filletHorizantalReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I capped the ends of the square tubing with some 1/4" X 2" plate....Just for looks.Here is the axle mountHere is the side ready for the reel mount.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Cool build so far. Hey - why not pulse spray mig the rust right off that band saw?  John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com