80 pieces

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Here is a bunch of tubes and flanges (80 of each).  Tube is 1/4" wall, flange are 1 1/4".  These have to be air tight.Here is what he wanted, but didn't have time to make a mold.And here are a few of mine.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I welded some with the MIG, but had too many leaks.Then I went over the ones I migged that leaked.   Next I tigged them.  Much better, NO leaks.Here is the test fixture.  I am testing them at 150 or so Psi.12 done, He wants a price.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:thats quite a bit of welding to be done! What is it, a linear foot if you were to straighten it out? times 80. It looks great though, wish I could lay down some beads like that.
Reply:Here is my home made high speed air cooled manually operated positioner.  Its a spindle off a scrapped trailer.this is set up ready to weld. I have 1/4" to work with.Here are some done.   200 amps, 3/32 red......  Thanks for watchingDavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:You have to test each one?? Any idea why the migged ones leaked?
Reply:David R,You need a real turn table for jobs like this.
Reply:Bet that sucker is HOT when you are done with it  LOLGood Luck DaveMe!
Reply:Uh, do you weld "the other side" too?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:Do you have pulse on your Tig?  If you do, try one with it and see the difference.
Reply:Originally Posted by SandyYou have to test each one?? Any idea why the migged ones leaked?
Reply:David what about spray arc with your Mig?Lincoln Power Mig 200Ready Welder spool gunLincoln Tomb Stone AC DCMPM 150 AMP DC portable Arc welder and GeneratorRiland 40 AMP Plazma Cutter
Reply:I know this isn't the info you're looking for, but, sub-arc with a positioner is the set-up for that job !Anything worth doing is worth doing RIGHT
Reply:When I worked in a weld shop doing aircraft work doing setups (I didn't weld) similar jobs were done in a slow turning lathe type unit with the welding unit  held by a rigid arm and adjusted by the welder watching and adjusting thru a rigid screen.  He didn't hold the torch and didn't wear a helmet.It looks like a turntable geared to a roticerie motor and a torch and screen held by visegrips could make a tool in a half hour that would automate that process and make consistant welds.Just an idea----
Reply:Originally Posted by KnotboredWhen I worked in a weld shop doing aircraft work doing setups (I didn't weld) similar jobs were done in a slow turning lathe type unit with the welding unit  held by a rigid arm and adjusted by the welder watching and adjusting thru a rigid screen.  He didn't hold the torch and didn't wear a helmet.
Reply:The welds look nice and that's a pretty good order.  Boy, doesn't it always go that you never need a tool until you REALLY need it, like a positioner right now.  Not sure what they are for, but do you think it would be prudent to sacrifice one piece to cut it open to check penetration?  That's a thick flange, 600psi?We had a problem back it the late eighties where there were a lot of Chinese flanges being used in pipeliene construction that had to be replaced because of impurities and voids in the fillet welds.  They cut up a bunch of them open and it was amazing what they looked like inside, while you'd never know it on the outside.  They  were all 300psi flanges.Last edited by Rick Moran; 12-10-2007 at 10:32 AM.Hobart 140 Handler w/ gasHyperTherm Powermax 380 Plasmaoxy/acetylene
Reply:[QUOTE=olddad]That would be a make-shift positioner and sub-arc set-up. If he has a machine with enough volts to do the job, he could fab up his own set-up as you suggested.[QUOTE]You can just jig up the mig gun and use it that way also.  For long welds in a turntable, it beats holding the gun up the whole time.If it were me doing this job, I'd have whipped out the turntable, and ran one pass around the outside of each one...and been done in less than a day.  The testing would have taken twice as long as the welding.  Work smart..and you'll work fast.Did he specifically ask for them to be tested?  I'd not have tested them unless requested (and paid for).
Reply:Nice job Dave and cool looking welds.Keep up the good work.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Originally Posted by TBDDavid what about spray arc with your Mig?
Reply:Originally Posted by EngloidIf it were me doing this job, I'd have whipped out the turntable, and ran one pass around the outside of each one...and been done in less than a day.  The testing would have taken twice as long as the welding.  Work smart..and you'll work fast.Did he specifically ask for them to be tested?  I'd not have tested them unless requested (and paid for).
Reply:Originally Posted by David RAlso thinking of Cored wire with gas.  That stuff lays in nice and flat.  I have a roll of .045 ESAB 7100 Ultra.David
Reply:Originally Posted by EngloidAs a matter of preference, I wouldn't reccomend changing processes in middle of a project...so that they all look the same.
Reply:I would say nice work, but I do not see the pictures.
Reply:Originally Posted by David RA smaller cup helped with the width of the arc.  So does looking through the bottom of my glasses David
Reply:Originally Posted by David RHere is a bunch of tubes and flanges (80 of each).  Tube is 1/4" wall, flange are 1 1/4".  These have to be air tight.Here is what he wanted, but didn't have time to make a mold.And here are a few of mine.
Reply:Originally Posted by David RHere is a bunch of tubes and flanges (80 of each).  Tube is 1/4" wall, flange are 1 1/4".  These have to be air tight.Here is what he wanted, but didn't have time to make a mold.And here are a few of mine.I ain't no pipe fitter, but why you would need a 1-1/4" plate flange on a system running at 5 psi is beyond me. Is that an ANSI flange ?
Reply:These are for oil coolers.  I don't design em, just weld em.  Could be something to do with vibration.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by TinbasherI ain't no pipe fitter, but why you would need a 1-1/4" plate flange on a system running at 5 psi is beyond me. Is that an ANSI flange ?
Reply:IT's not me doing it, but , if I were, i'd do it (weld) the old fashion way.  Stick weld . When it gets down to quality , it's STILL the best ,for many jobs . And i've worked around most of the processes- mig,tig,spray arc, sub-arc,innershield,outershield,etc.    just think, a hundred years ago , they probably would have oxy-acetylene welded them[SIZE="5"Yardbird"
Reply:Today I hooked up a 3' ground wire to my "positioner".  It almost turns by its self, I just push with the filler rod and it turns while I am welding it.I tigged 12 of em today on the inside.  No leaks.  It took me 1/2 hour to test 7 of them.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I can see the pics now.Nice
Reply:I have done 1/2 of the job.  They are picking them up 12 at a time. I came up with a price of $12.85 each, but will discount that a little.  Still no advanced panel for my V350.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David REdit:  Today I tried pulse.  185 amps, back ground 160, 2.5 Hz....No balls.  I was thinking of using the V350.    David
Reply:Pulser, You are right, the machine is just big enough to do the job.  Today I had it on 185/125  50% .8hz.  I was going ahead and back on each pulse dipping on every other pulse.  It worked well.  OK, on for the good news.  The panel came in.  I picked it up after lunch.  Installed it and messed around on some 3/8 plate before I put it to work.I now have pulsed spray Mig.   All I can say is I am truly Amazed.  I was doing about 6 an hour with the tig.  Today I did 40 in two hours.  Just welding the inside.   I'll let the pics speak for it.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Nice, I need one nowDisclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:I Modified my positioner.Here is some TIGI really enjoyed doing these.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Now for the real fun!Pulsed spray MIG.I have more pics, but I got a date tonight Real world weldin.  When I grow up I want to be a tig weldor.
Reply:OK, settings.  What is in the picture.  Wire feeder on 300 ipm, Machine on 350 ipm  Arc control or what ever it is, +5.  Ag8.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:That is slicker than $hit, I like it.Disclaimer; "I am just an a$$hole welder, don't take it personally ."