How would you weld this?

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I'm about to weld about a 100+ 3/8" SS rods to 1/4" SS plates as shown in the attached image.How would you go about it?1. What would be the best equipment to use?2. What's the best weld type for this application?3. Any general advice would be really appreciated. I'm going to be welding so many of these that I wan't to make sure I'm doing it right.Thanks, Danny
Reply:All stainless? I'd be tempted to drill the plates, insert the rods and tig them in from behind rather than the way they did them in that pict.Small round stock like shown in the picts is a PITA to weld either with mig or tig. It's tough to get the gun or torch around fast enough with something that small. If you weld from the back, then you have a flat surface and can simply weld then in no problem..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:What are they used for? What kind of pressures/weight/forces are put on them? What machines do you have access to?
Reply:I'm going to use them as table legs. They'll need to withstand about 500lbs of weight.I'm going to buy new equipment for this job, any recommendations would be helpful.
Reply:stainless stick
Reply:Originally Posted by bittikerI'm going to buy new equipment for this job, any recommendations would be helpful.
Reply:I would tig them. I did 750 of these, 100 won't take long. Sorry the pics are all sideways  Attached ImagesAirco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:I'm an amateur welder at best. I'm trying to go with the most fool-proof method. If I drilled a hole, and welded from the back, would I drill a slightly bigger hole? Or use the same dia. drill bit?Also, if I were to weld from the back, could I use this MIG welder? Or would I need something more heavy duty?http://www.amazon.com/Pro-Series-MMI...1&keywords=kit
Reply:I'd go with the same size hole myself.That welder isn't really the right tool for stainless if you want it to stay stainless. For that you will want a mig that uses gas vs a small flux core welder. Understand to mig stainless it will not be cheap. Stainless mig usually uses a trimix gas specifically for stainless. My supplier doesn't usually stock small cylinders of this gas, but can order then is as needed. It is not cheap..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
Reply:Ditto DSW, I'd punch them out on the ironworker and tig from the back. Update your user cp with your location and you might find somebody willing to help you  out.   100 of them isn't a lot, maybe a days work.
Reply:You'd do way better with the punch and weld from the back method.  The welding from the back method is just a flat weld, and you'll be able to do 5 of them in the time it would take to do 1 of the flllet weld around a very small rod method shown in the pics, plus if you're not experienced in doing the small circumference of the fillet weld method, you'll have a substantial learning curve before you get to production....SquirmyPig, what is that thing used for?
Reply:Are they for a restaurant or something?  All on one table? Or 25 tables?  For your use? Or did you accept a job you weren't ready for?My name's not Jim....
Reply:Mr. Moose,   Duh, It's a dime holder.  Bittiker Learn to weld first,  Seems like a serious project 500 lbs capacity. Not a lot a weld to hide your lack of ability.   Might want to pay somebody to do it.  Good luck
Reply:drilling stainless is a chore if you have never done that before.  I would second the punch, but many shops will charge more for punching stainless than for punching mild steel.  Lastly, I am not sure he knows how to tig.  Stick welding from the back would be cheaper in the long run due to needing just a cracker box.  if he already had a cracker box and wanted to add a tig stinger to it then he is looking at another 200-300 dollars. on the cheap.
Reply:That looks like the same high dollar gig set I use from time to time.
Reply:Here's another vote for punching the holes and welding from the back. Don't attempt to drill the holes yourself, you'll regret it - just outsource.Make sure you have a jig set up so that everything slots into place nicely at the required angles/heights.Have it so that the rod is recessed slightly from the back of the plate, so the weld bead doesn't protrude above the face of the plate (assuming you want to keep it flat).I'd reach straight for a tig machine - you'll get a quick neat weld with no cleanup required.When you get the holes punched, they'll probably come back with oil and crap on them, so you'd be best advised to dunk them all in a cleaning solution and a wipe down with acetone before welding.
Reply:Mr.Moose, the name is SquirmyPug  and the part is an adjustment handle for a tool called a Knucklemate..something I don't think anyone here has used .Scott Young..it is high dollar it has made us alot of $$ Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:Can you buy them for less than making them?http://hairpinlegs.com/products.php?id=1If you decided to have the holes punched or drilled remember that the legs are cambered a few degrees. I'd lay out my fixture and then experiment with the hole size as you likely need to oversize a little. In an ideal world you'd drill the holes at the appropriate angles for the camber but angled holes cost more than flat drilled or punched. Do the exposed welds have an aesthetics value?
Reply:Originally Posted by TimmyTIGstainless stick
Reply:knucklemate,,, appears to be for loco/ car knuckles..   hmm, learn something new every day .L-Tec PCM-VPi II Hobart Handler140Millermatic 35Lincoln Power arc 4000Lincoln Ranger 10,000 ( 3 ) Longevity Tigweld 160SX Purox O/A setup100lb anvilXLO/servosource cnc mill
Reply:drill the holeinsert the rod half way throught he plate,  leave it about 1/8" from flush on the back side,  and weld it up with the mig. it the wel is beyond flush grinder down!
Reply:Those plates in the sample don't look 1/4 to me, if the rods are 3/8Experience is something you get right after you need it
Reply:you're building a 500 pound table with those little rods for legs?
Reply:I apologize if I'm wrong, but is this spam?The OP wants to weld up something to withstand 500lb, stresses, seems to have no idea of the equipment or processes or difficulty involved and asks if a 110V flux core machine is up to the task.    I'm just wondering ......If not: I like the punching or option and weld from the back, but would it be reasonable with limited equipment options I am assuming the OP has available to tig the fillet and stop a couple times to turn the piece, since it is difficult to manipulate around the small diameter without a turntable positioner? How about some simple positioner kinda like the old sit n spin kids toy you could spin with your foot?Last edited by jtcnj; 01-02-2013 at 09:03 PM.Lincoln AC/DC 225/125 and WP17. 75A AC is for pipe thawing!HH 140 - new addtion 9/2012.I didn't agree, but hoped for Hope and Change.I got change for myself and my family: for the worse.This is the reality of: Barackalypse Now. Again.
Reply:Originally Posted by jtcnjI apologize if I'm wrong, but is this spam?The OP wants to weld up something to withstand 500lb, stresses, seems to have no idea of the equipment or processes or difficulty involved and asks if a 110V flux core machine is up to the task.    I'm just wondering ......each leg is two 3/8 rods that form a v and there are 4 legs thus 8 rods.  each leg holds up to 125 lbs under compression so I don't see where that is too much weight.Just my understanding. I don't see it as spam.  I see spam as the likes of sellers or people trying to move traffic to other websites for monetary gain.
Reply:Originally Posted by Scott Youngeach leg is two 3/8 rods that form a v and there are 4 legs thus 8 rods.  each leg holds up to 125 lbs under compression so I don't see where that is too much weight.Just my understanding. I don't see it as spam.  I see spam as the likes of sellers or people trying to move traffic to other websites for monetary gain.
Reply:Originally Posted by Scott YoungJust my understanding. I don't see it as spam.  I see spam as the likes of sellers or people trying to move traffic to other websites for monetary gain.
Reply:Not spam, just an overly optimistic woodworker.I got some reasonable quotes from a local san francisco shop, and decided for now I'm just going to purchase the legs. I figured if I only had one type of weld to learn, I could figure it out on my own... but I realized welding is a world of its own. I'll learn eventually.Thanks for all your help!Here are the tables I'm hoping to build:www.stemfurniture.com
Reply:Originally Posted by bittikerjust an overly optimistic woodworker.
Reply:I think he might weld photobooths for a hobby.
Reply:Id use a welder.I forgot how to change this.
Reply:Thanks everyone for your help! I finished 13 tables with this method, check them out here:http://www.stemfurniture.com-Danny
Reply:The tables look nice Bittiker.Airco Ac/Dc 300 HeliwelderMillerMatic 200 (stolen)Miller Maxstar 150STLMiller AEAD200LE (welding and generating power) Hobart MIG
Reply:I would agree they look good.Welding is a world of it own.  That does not mean you cannot learn though.Either taking a class and staying on here, or even just buying a welder and start playing around with some stuff.
Reply:A wood worker cum welder.....now I've heard it all.It is little wonder the USA has lost most of it's ability to produce trade goods against the Chinese "back yarders"......I weep.In this situation the wood worker is taking the bread out of the mouth of a person who relies on welding for a living and can guarantee his work.If the table leg fails at the weld and the customer ends up with hot soup amongst the family jewels.....expect some expensive court time due to also attempting to be a lawyer.....LOL.Ian.
Reply:Originally Posted by bittikerThanks everyone for your help! I finished 13 tables with this method, check them out here:http://www.stemfurniture.com-Danny
Reply:Originally Posted by puddytatA wood worker cum welder.....now I've heard it all.It is little wonder the USA has lost most of it's ability to produce trade goods against the Chinese "back yarders"......I weep.In this situation the wood worker is taking the bread out of the mouth of a person who relies on welding for a living and can guarantee his work.If the table leg fails at the weld and the customer ends up with hot soup amongst the family jewels.....expect some expensive court time due to also attempting to be a lawyer.....LOL.Ian.
Reply:$2199 for a table
Reply:Originally Posted by puddytatA wood worker cum welder.....now I've heard it all.It is little wonder the USA has lost most of it's ability to produce trade goods against the Chinese "back yarders"......I weep.In this situation the wood worker is taking the bread out of the mouth of a person who relies on welding for a living and can guarantee his work.If the table leg fails at the weld and the customer ends up with hot soup amongst the family jewels.....expect some expensive court time due to also attempting to be a lawyer.....LOL.Ian.
Reply:bittiker, I like your tables and the fact that you are using material that would otherwise be discarded to make functional and good looking things.  If you are in an area where you can sell your products for enough to make a business out of it, all the better.Most of us have a personality trait that causes us to enjoy making things, and learning new skills.  You came and asked a reasonable question.  You got some good advice on that question, and if you find that welding is a skill that would take you further down the road to where you want to go, I'm sure you'll do well with some practice and focus.  Good luck!
Reply:I'd like to see the welds on that 2k $ table--------------------------------------------------------------www.becmotors.nlyup, I quit welding.. joined welder anonymous
Reply:In my area every single person that would want a table like that would make their own. Pretty tough to do something that makes money around here. You have to be good at something that is very hard to do around these parts and then still no one has money. lol
Reply:Originally Posted by SquirmyPugNot sure what you are saying here...
Reply:Originally Posted by SquirmyPugYou are right on the spam..But I'm still not sure.
Reply:He is based in Los Gatos.... Probably has a hard time keeping them in stock.
Reply:It's crazy on these threads how a simple welding question can get such intense reactions out of people. Thanks everyone for your input, I've got my hands full marketing now, but I'll have more questions once I get back in the shop - DannyLast edited by bittiker; 04-23-2013 at 02:57 PM.
Reply:Good stuff! If you have buyers all power to you! They do look nice!
Reply:Originally Posted by jmanOMFG... seriously?   Paranoid or Impatient much?  It had only been 26 hours since the OP's initial post!  Now 'Moderators' are implying that people might be 'TROLLS' because they don't answer fast enough?  Christ, It's a wonder people come here for  at all....