Easter egg drop roll cage

admin

My family does an annual egg drop contest for Easter, so I thought I'd incorporate my new hobby in this year's design.  The only rule this year was that you had to be able to see the egg from the outside. (last year people were burying their eggs in huge boxes full of foam and bubble wrap which took a few mins to unwrap).  Please be nice, as I'm a complete welding newb (I've almost emptied my first 155cf of argon to give you an idea)  Just thought I'd share a fun project.The roll cage is made from ~.125 rod that I got from a scrapped chrome wire utility shelf.  I have an AHP Alphatig (2015), and had it set around 80 amps.  1/16" 2% lanth electrode.  Fusion welds at first, and then decided to use a bit of filler on the inside point of each corner.  I don't think adding the filler went well, but hopefully it will add a little strength.  Everything looked good on the top and bottom squares, but things went south when I started doing the connecting T joints.  A few of the corners have bad porosity after doing the T, not sure what happened.   Any suggestions on how I could avoid it?Top and bottom pieces, fusion welds looked pretty good at this point.So ugly, but should hold for what I need.  Wish I knew what caused this...Locked and loaded.Closeup of the custom egg holder.  I cut the plates out of .1" fiberglass sheet on my cheap Chinese 3040 cnc router.I initially wanted to have just the roll cage, but it was deforming pretty bad when I tested from about 2 stories.  I decided to enclose in cardbard, which ended up working really well.Thanks for looking, and Happy Easter!!
Reply:Love it. I'm a science teacher and have done a few egg drops over the years. Please post results and more info about height and such.Dave ReberWadsworth Ohio
Reply:do you cheat and hard boil it first?..lolOf all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Did you grind off the chrome plating first?
Reply:nice design! hope you win!VictorPraxairAir LiquideMillerLincoln Electric
Reply:you should have been able to just autogenous those bars together with no filler and it would come out stronger. That issue looks like porosity from your filler wire maybe? that chrome plating could have interacted with the filler and created porosity. OR dissimilar metals reacting, filler wire could be the wrong type? BUT its a cool design and idea! good luck with the egg drop!
Reply:Originally Posted by SupeDid you grind off the chrome plating first?