Aluminum Cabinet Doors............

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A co-worker asked me to make her some new doors for her outdoor grill area......She has wood doors now and they are starting to deteriorate in the weather......A few pics of the current situation.......Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:The area is a disaster..... All of the doors are different dimensions.......  Anyway..... I am doing new doors with Aluminum......I have done a mock door so that i can test the limits of my machine and my breaker.....I have a Precision TIG 185 with 50 Amp service.......Here is what I found on my test mock piece.......150 amps...... breaker trips........ 140 amps..... no breaker trip...... but just barely enough power to do 1/8th aluminum..... with no penetration.......... only cosmetic......A couple Pics of the test piece....... I made notes all over it....Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Today I welded the 7 outside pieces to the doors...... I still have to weld the 1/8th doors on...... but nonetheless I have part of the job done.......I will post the finished product here when done..... but so far......... i have a part of it done.......PICS........Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:My machine sticks me to 60 Hz.... but I would rather do this job at 150 Hz.........That and a water cooled torch that goes over 140 amps without flipping the darn breaker................Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Looks good. What size is the stock for the frame of the doors?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Everything is 1/8th inch......The doors are 1/8th inch 6061 - T6......The trim are the same..........Of course if you put 1/8th" trim and try to weld it to 1/8th sheet...... 140 amps won't cut it.....Vertical up helps......but really it's not enough......I might take this to school and use the machines there to finish up the job...........Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Right, but is that 1" x 2"?Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:The leg is 1/2" and it's 1.5" across........Is that what you mean?Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:150 amps is tripping a 50amp breaker? You might have a weak breaker, could be a good idea to replace it and check if you can get more power from the welder.The doors are looking nice, if I was doing it I would use brushed stainless to match the appliances . Less amps and (to me) looks nicer.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:What about cutting the panel a little over sized and simply riveting them to the back of the frame? Would be alot simpler and have a cleaner look IMO.If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:If you haven't done it yet, I think a simple design change will make your doors turn out drastically better.Looks to me like you have your perimeter frames fabricated (the rec. tube), but don't yet have the sheet attached yet.  If that's the case, you're golden.  Now, cut your sheet smaller than the frame by 1/8-3/16 all the way around (total dimension would be 1/4-3/8 smaller than the tube).  Ditch your inside fillet.  There is nothing worse than trying to weld a fillet like that with 60 Hz.  Center your new panel over the frame, where you have your 1/8-3/16 gap all the way around.  Then, run your stitch welds out here.  That joint will be more conducive to your 60 Hz (ugh!) and potentially only 140 amps.  But, most importantly, it will significantly limit distortion.  The fillets on the inside of the frame will try to pull the door sheet out of shape, but the lap welds around the ledge will allow for a much greater margin of error before causing any real noticeable distortion.Who is John Galt?
Reply:Great idea.........I have made the perimeters about 1/8th bigger than the sheet all the way around so I can weld from the back....... I think I'm going to ditch the fillets because I don't have enough heat for it.........Time for a bigger machine.........Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Originally Posted by FexalGreat idea.........I have made the perimeters about 1/8th bigger than the sheet all the way around so I can weld from the back....... I think I'm going to ditch the fillets because I don't have enough heat for it.........Time for a bigger machine.........
Reply:Sounds as if you need a bigger/heavier circuit first Fex.  Turned out a heck of a lot better than the cheap assed recycled stop sign doors I didLincoln PrecisionTig 275Miller 251Miller DialArc 250Bridgeport millHossfeld bender & diesLogan shaperJet 14 X 40 latheSouth Bend 9" 'C'Hypertherm 900Ellis 3000 band saw21"Royersford ExcelsiorTwo shops, still too many tools.
Reply:either the screws in the back or just plug weld it from the back  then the only welds exposed on the front are the mitered corners which you could either leave go or flap disk
Reply:Originally Posted by FexalI have a Precision TIG 185 with 50 Amp service.......Here is what I found on my test mock piece.......150 amps...... breaker trips........ 140 amps..... no breaker trip...... but just barely enough power to do 1/8th aluminum..... with no penetration.......... only cosmetic......
Reply:looks like your coming along great!  love to see the finished product
Reply:A little update for this Saturday's effort in the garage.......I got the back pieces welded to the perimeter pieces........ A total of 8" of weld all the way around on each door...... minimal to almost no distortion....  no fillet welds at all were needed.... i welded the backs only and then flapped them down........Now I need to put the handles on........ and then once on-site I will rivet the hinges and hooks on.....A couple pics from today....... Happy so far......Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Looking good, have you gotten the doors mounted yet?
Reply:Not yet...... I'm on Ava duty all this weekend and then out of town next weekend.......it's looking like it will be the second weekend in December before I can go over to mount them........I'll post pics.......Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Great job FEXAL, they look dynamite! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Great looking doors! How did it happen thg the original doors were so randomly sized?Lincoln Precision Tig 185Lincoln Power Mig 256Hypertherm PM 45Everlast 140STSmith O/A
Reply:Those look real nice, good work!Millermatic 135Craftsman 7 Hp 80 Gallon           2 stage compressor
Reply:Well today i finally got over to the customer's house to finish installing the doors.......With Saturday's as pretty much my only day.... it has managed to rain for a few of them...... then she was out of town for 1 or 2 of them...... so.... today was the day to finish the job and collect the other half......I also had Ava to help me..... she was there to take a few photos with the camera.......... The only one for sure is the pic of me..... but some of the others mixed in were taken by Ava too....Pics of the finished job.......Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Nice! Real nice!Turned out really well! How do they latch?
Reply:They latch by way of what Lowes calls a Gatehouse Cabinet Latch: http://www.lowes.com/pd_233964-53458...are&facetInfo=They clip in really secure..... I JB Welded the latch to the door and then screwed the ball portion to the inside of the opening......Latches work like a charm....All hidden.... leaving a clean appearance.......Precision TIG 185 and MP 210Bobcat 225NTCutmaster 42O/A tanks.... 2 Argon tanks...... 2 C25 TanksFacebook...... F2 Metal WorksETSY....... https://www.etsy.com/shop/F2MetalWorksF2MetalWorks.com....... http://www.f2metalworks.com/
Reply:Very nice - looks much better than the wood doors Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Great job Fex! BTW, keep that helper happy.Lincoln PrecisionTig 275Miller 251Miller DialArc 250Bridgeport millHossfeld bender & diesLogan shaperJet 14 X 40 latheSouth Bend 9" 'C'Hypertherm 900Ellis 3000 band saw21"Royersford ExcelsiorTwo shops, still too many tools.