Today's work

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Cell tower project, add gussets to strengthen the base to the tower.  The customer had added a bunch of support and I get to do the final finish. Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.
Reply:There are 18 of these.  Here is a closer view.  Same settings, .045 bare wire, Co2 gas, 150 ipm, 19 volts.  The base is 1.5", so I turn the wire up to 200 and volts up to 21.  Gussets measure 3/4 X 15" X 5" Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.
Reply:EDITED:how many passes in the bottom weld? what does the book says? Seems pretty low on the heat to me How thick is the structure and gusset?Last edited by elvergon; 06-08-2007 at 04:32 PM.My Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:For some reason, today the mig gun got too hot to hang on to even with gloves.  It was about 90*f.  I even took apart the gun to make sure the connection inside was OK.  Its a Lincoln magnum 300.  I am at about 165 amps, but welding for 40 minutes per piece.  At 2:00, I couldn't take the heat so packed up my stuff and went home to sit under the AC.  Tomrrow I will start about 5:30 to beat the heat.  Job should take 3 days give or take.  It takes about an hour or so to grind off the galvanize and weld the piece on both sides and bottom.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by elvergonEDITED:how many passes in the bottom weld? what does the book says? Seems pretty low on the heat to me How thick is the structure and gusset?
Reply:Have you experimented with spray arc using 98/2%?  I believe this would be great for this ;however, the vertical can be tough.I say whats done looks great  keep doing it. I know I get worried about my gun when its really hot. weld it like you own it
Reply:OBTW  The cell towers,smoke stacks, cooling towers at nuke plants, and 1700ft tall towers was my job back in mid 90s.  I was the guy changing the bulbs.  Yeah the stories I could tell weld it like you own it
Reply:Going to the job and coming home were the best part.  First job for the new truck. Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I never could get more than one pic in a post.David  Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Just curious, whats the reason that you didnt stick weld those on?Lots of toys.
Reply:thats a fair job mate lot of welding in it ,  im curious aswell brandon , why didnt you stick weld it mate , looks like a bit of a tight job with them nuts and bolt ends in the way there
Reply:Hey, Can you forgive one more question from a newbie?  Those vert's look like a root with maybe 2 cover passes?  Why not use stringers?  And those are vert ups? Nice.  I know you just weld it like they want it, and that's the bottom line.  I guess I'm wondering what makes someone decide they want this-vs.-that, in this case for example, why up?  Not second-guessing ya'll,  just asking because I don't know....Nice rig, too!  Hang in there, winter is just around the corner...
Reply:going up gives more penetration, you should check the thread of David too in which he compares up and down MIG welding... You´ll be amazed...At least that´s the most logical reason that comes to my mind!I like the close up...those welds are beautifulMy Babies: HF Drill pressHF Pipe Bender3   4.5" Black and Decker angle grindersLincoln Electric PROMIG 175that´s it!
Reply:Just wondering.  Why 045 wire instead of something heavier?  Seems sort of thin for such thick material.
Reply:Originally Posted by brandon75173Just curious, whats the reason that you didnt stick weld those on?
Reply:very nice david how do you get them flat like that,your past verticles were more built in the middle.you must be doing something different ,lower power perhaps?
Reply:Originally Posted by David RWelderboy,Most of what I use is .045.  I never tried anything bigger.  For me it works great.  My feeder will push .052 or .0625, but That is some big stuff.  Going up, I think .045 is as big as I can handle.
Reply:Originally Posted by pipe fittervery nice david how do you get them flat like that,your past verticles were more built in the middle.you must be doing something different ,lower power perhaps?
Reply:I went to work today to do some stuff.  While I was there, I expermented on some 3/4 plate.  I am trying to get a better weld on the base.  I ran the LN-25 at 300 ips with .045 wire and Co2 gas.  Inductance on 10, Volts at 26.  I hooked up an ampmeter, it was around 220 amps.  I had a nice bead with minimal spatter.  Tuesday I go back to attempt to finish the job.  i will try that setting on the base of the gussets.After playing around for a while at the high settings, the whole 300 amp mig gun was smoking.  Good thing its only 5" of weld.  I also tried 350 ips @ 28 volts, but it was a little hard for me to control.  Probably pushing it too far.  DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by David RThe wire is much faster.  I stick weld when its windy.  I also have some self shielding wire thats a bear to run up hill.  I would rather stick weld than use the NR-233.  UP is the ONLY way to go for structural.  These welds will be AWS inspected when I am done.  NO undercutting over 1/32", Porisity is allowed, one hole in 4" of weld.  I doubt there is any.  ALL spatter must be removed before 2 coats of bursh on cold galv.  If its not right, I go  back and do it over for free.Mjj,That is ONE pass, supposed to be a 3/8 fillet which is what it is.  I am going to have my daughter the photographer try to film a bead.  Its fun to watch.Welderboy,Most of what I use is .045.  I never tried anything bigger.  For me it works great.  My feeder will push .052 or .0625, but That is some big stuff.  Going up, I think .045 is as big as I can handle.Its cooler today, I am off to do a bunch more.  14 left.  Too bad I had to quit early, but the heat was killing me.David
Reply:Originally Posted by brandon75173I hear you, the only option I have is to run 7018.  I have the base D1.1 cert and it doesnt cover wire so thats my only option for now.
Reply:Originally Posted by David RThe only cert I have is for wire 3G unlimited thickness.  I can run stick as well, but for me wire is where its at.  I was runing 5/32 7024 on the base, but it still took 3 passes and doesen't run as well on DC as it does on AC.  I no longer have AC welding output.  I also have used 5/32 7018 for the base, same thing 3 passes at least.  I bought 20 lbs of 3/16 7018 just for these jobs, but I have not run it yet.  Tomorrow I am leaving EARLY to beat the heat and will try the 300 ipm @ 26 volts to see how it does on the base.  When I bought the ranger 250, I aslo bought a remote control on a 100' cord.  I can set it right on the LN-25 and make all adjustments from there.David
Reply:I have had my LN-25 almost as long as I had a gas welder.  It always had .045 wire in it.  I have built a lot of stuff over the years with that combination.  I was practicing with 7018 for a long time for the 3G test.  One day I tried it with the wire and after just a few more runs I took the test.  Now I think I can pass the test with 7018.  For the CWIs, its the same destructive testing for wire as rod.  I always ask before I get out the wire feed.   And yes the ranger 250 has plenty of balls.  It will gouge with 3/16 all day.  1/4" is too big for it.  It will run 3/16 7018.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:I finished the job today.  It was windy so I did some stick.  1/8 7018 verticle up.  Its hard to see, but this weld is a little concave.  I have been using a different weave and it really works.  I am trying to get my daughter to film it.  This is the first time I tried it with  stick, its always been with wire, but it doesn't seem to matter.You can see where I grind the galv off the tower. Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.
Reply:And the settings:Hourmeter reads 199.9 Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.the finished product.  About 30 hours in the job including travel. Attached ImagesReal world weldin.  When I grow up I want to be a tig weldor.
Reply:good lookin work63' Lincoln SA200 2008 miller trailblazer 302fibre-metal pipelinermiller camo BWEand all the guns and ammo a growin boy needs
Reply:nice,very nice
Reply:nice work David Creative metal Creative metal Facebook
Reply:I didn't realize the Ranger 250 lacked AC. What's up with that? My Ranger 9 has AC/DC. I thought the 250 was a step up?Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Originally Posted by Joker11I didn't realize the Ranger 250 lacked AC. What's up with that? My Ranger 9 has AC/DC. I thought the 250 was a step up?
Reply:keep the pics comming Dave there lookin good63' Lincoln SA200 2008 miller trailblazer 302fibre-metal pipelinermiller camo BWEand all the guns and ammo a growin boy needs