Jig for grates.

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I am building a BBQ grill, these are the grates for it.  I think it takes 6 or 7 of this size.    Then last week I got an order from the same people for 12 more.  First my new tig.,  Water cooler, #18 torch.  I had the power supply with foot pedal.Material is 5/8" cold rolled square. 10 - 12 foot lengths welded together on one end.All I had was 1/4 X 6 so I made it 2 wide.   Great measures 11.5 X 23.  I had my son pick up some 1/2" round stock to use as spacers.  I measured the grates on another grill.Awe Sheiss!  Off by  5/8"  Cut em off and start over....DAvidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Some welds:Tig, E70S-6  max 300 amps which I never used.  3/32 tungstenRedone.  I used a piece of 1/16" filler wire as a spacerYer gonna ask, Yes I ground the ends but not to a point, 1/8 to 1/4" root.  but a decent single V on both sides.Last edited by David R; 12-10-2011 at 03:02 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Man, those should last a good while David! I also like your TIG set up, 3 phase DC makes for some real smooth running.Matt
Reply:Very nice! I've been working on something similar using 7/16 round for spacers it was a pain getting everything lined up and square. your way looks much more straight forward. this is getting bookmarked.
Reply:Thank you.V350 is single phase, but not de rated.  All tig welds were touch start with the new torch.   Just getting the hang of it.  I was a little heavy footed on some and boiled the filler so they get ground out and re done.  Pics of the porosity tomorrow.I made 2 grates they fell right out of the jig.  Probably 2 more today then I need a LOT more square stock.  These are copies of what the customer already has.David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I have done a total of 4 now.  Here is the porosity.   Only a few welds, Usually on the end one.   I ground them out and re did them.  The porosity was deeper than my welds.   Bars were beveled.  I had the torch on 300 and was trying to burn the weld in deeper.  I just plain got it too hot.     Only about 5 - 10 of the 160 welds looked like this.Gas lens on, gas lens off, #8 cup.   Actually by my gauge 5 to 7 LPM.Not happy with them yet, I should be able to just touch them with a flap disk.  I will grind a bigger groove on the next ones, make more passes cooler.When these start bubbling, junk comes out of the puddle on the tungsten or a gas lens. DavidLast edited by David R; 12-12-2011 at 07:33 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Looks great David!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