Aluminum Cooling Tubes..

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I have 12 aluminum cooling tubes staring me in the face so I guess it's time to get started..Armed with my trusty die grinder and a file one must prep the tube ends and the insert blocks before welding..Pics are in order..# 1..Tubing size..These are also 110 inches long so standing them up to weld is NOT an option..# 2.. Block drilled and tapped 1/2 N.P.T...(Make sure they are installed CORRECTLY)...# 3.. Prepped and ready to go..# 4 and 5..Done.All welding done "Sideways"..3/32" Red..Machine on "Kill"..1/16" 4043 filler..PEDAL!!!!I was also informed to NOT let the weld go to the outside edges at all so they will sit flat without any post grinding needed.."Yeah...whatever"I get all the fun jobs.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Great example of welding thick to thin as was asked in a recent thread...Tiger Sales:  AHP Distributor    www.tigersalesco.comAHP200x; AHP 160ST; MM350P,  Spoolmatic 30A; Everlast PowerTig 185; Thermal Dynamics 60i plasma.  For Sale:  Cobra Mig 250 w/ Push-pull gun.  Lincoln Wirematic 250
Reply:Do you check for leaks on something that big?  Or just call it good enough?
Reply:Very impressive as always.
Reply:looks good as usual zapMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Lookin good, Zap!
Reply:Looks good Zap!!  A question for you tho..I always see the famous 1966 dime just curious is that ur born on date or just the lucky dime??
Reply:Originally Posted by AcemanDo you check for leaks on something that big?  Or just call it good enough?
Reply:Originally Posted by powerLooks good Zap!!  A question for you tho..I always see the famous 1966 dime just curious is that ur born on date or just the lucky dime??
Reply:ZAP your projects always impress me.  You get all the "good" jobs cause you are good at what you do.  "G"ConductorX - The Volkswright Shophttp://volkswright.blogspot.com/http://bugwerks.blogspot.com/Miller DVI w/Spoolgun - Miller Plasma Cutter
Reply:Originally Posted by zapsterI will pressure test these @60 PSI when done..They are shrunk in with .010 squeeze so they are in to stay..Me no worried.....zap!
Reply:You could have hung from the ceiling like "Mission Impossible" style.  Its time you started challenging yourself Zap.  No more run-of-the mill weaksauce from you, okay?-Aaronp.s.  Nice work man!Jet 17.5" Drill Press1942 South Bend 16x84 Lathe1980s Miller 320A / BP --- 2013 Power Mig 2562012 Jet 7x12 Horizontal BandsawVictor O/A Setup
Reply:set up a 10' step ladder and sit right on top to weld those things standing
Reply:Originally Posted by rabidchimpYou could have hung from the ceiling like "Mission Impossible" style.
Reply:I'd have been looking for a 7 foot "hole".  Maybe off a stairwell or similar.  End result looks nice.
Reply:Your too good for your own good mate
Reply:Originally Posted by Mr. MooseI'd have been looking for a 7 foot "hole".  Maybe off a stairwell or similar.
Reply:Originally Posted by GambleJust air, or do you fill them with water too?
Reply:Originally Posted by GambleJust air, or do you fill them with water too?
Reply:Originally Posted by dbotos1.5 times working pressure, hydrostatically tested is standard.  Don't pressure test with air unless your goal is to create a potential shrapnel bomb.Zap - did they spec any ASME code(s) on this?
Reply:Originally Posted by GambleSo do you fill it half or completely with water? This would be great info to know for later down the line.
Reply:Everything I test is at 60 PSI for this place that owns them..Here is a copper cooling chamber shaped like a comb that I made years ago..All carved out of solid copper but it ends up with 1/8" walls and a 1/8" copper plate top...I find the leaks if there is any with window cleaner then grind and re-weld..Been doing this for years...That's what they specify and that's what they get....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:The original aluminum tubes would be easy to hydro - only 1.4 gallons to fill.