Trailer Box

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I'm tired of having to share the cab with straps, winches, bars...............................This is a 12 x 48 x 15 box which will mount on the front of the headache rack on the trailer.  Just a simple box to carry tie down stuff.  I chose to mount it on the headache rack because of the configuration of the trailer, and the fact I don't want to weld on the trailer frame more than necessary.  In addition, I don't want to hang it from the crossmembers because the crossmembers will all be replaced in the future.  (Like what hasn't been replaced on that trailer  )The pieces are cut and fitted on the table fixture.  I like to show this simple fixture, it bugs me to the max to see some of the screwball things people put on their tables to hold stuff down or in place.  This is simple, removable, can be shimmed to exact level, and provides unlimited clamping surfaces.  Four pieces of angle iron carefully welded to be identical, and you're in business without all the fuss.The first step of final assembly of the frame.  The entire thing will be tacked before welding, not welded in sub assemblies.  The Sun Goddess came home early from work to catch some rays   If I wasn't busy I'da joined her   We do like our sun.  She's about the best thing that ever happened to this old guy.Probably have it mostly finished today."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Looks good. Good idea to get that stuff out of the cab not only for room but for safety in case you forbid are ever in a accident that chit flying around in the cab could hurt a fella.
Reply:Please keep us updated on progress, this is something I've been needing to do for my 24' gooseneck BADLY.
Reply:So your fixture is 2 pieces of angle, welded together to form a big 'C'?
Reply:Watch the flash burn on your helper.  Give her a lid and have her move closer.Dan
Reply:Did the finish welding on the frame yesterday.All tacking was done while clamped to the fixture.  And all tacks were on inside corners of each panel section.Self shielding flux core was used for all welds (.030)Next, the butt welds were made.  I prefer to make the butt welds first to lock the pieces in place before doing the fillets.Edges are a PITA.  Set the welder real low, and move fast.  These are ground flush later on. I finish out with all the fillets welded on the diagonals on each panel to keep it square.  These are hot fast welds.In order to make nice uniform welds when doing the fillets I grind out the tacks prior to welding.  The penetration, and what metal's left, will hold the joint secure, and the butt welds have already locked up much of any anticipated movement while the weld is cooling.Also..... I find it easier to do the butt welds first for another reason.  It's easier for me to wrap the fillet around to fuse with the butt weld instead of wraping the butt weld around to fuse with the fillet.  But that's just me More to follow............................................  ."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Did it warp??  YOU BETCHA I usually do the finish welding while the piece is off the fixture, it's easier to reach the weld joints.All welded joints were warped/distorted about like this.Shrinking to straighten was done with, and without, applied force.  Mild tweaks were done without force, and joints that need more movement to get back to square were done with some help.Only apply enough force to assist, and predict the amount of momement.  In the case of widening a gap caused by distortion I find force to be more predictable as I can fine tune the movement to keep within tolerances.Heat, in most cases is applied on either side of the joint.  You can see the heat is applied beyond the joint, not on top of it.  I can put up a diagram of the pattern later if anybody is interested.  For tubing it's a 3 sided heating patternMore to follow........................."Any day above ground is a good day"http://www.farmersamm.com/
Reply:So, how did it turn out??  Good enough for this ol' boy The sheet metal sits nice and flat, and the edges are true.  And all twist is gone.Usually I heat shrink at all stages of the build.  I don't wait until it's in the final stages.  You need to take the distortion out when it occurs or the next stage will turn out like crap........nothing fits."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Dog bumped my leg while I took this Anyhow, you get the idea.The tubing is heated in a wedge shape on two sides, and straight across on the top.  The underside (the part you don't want to shrink) is left unheated."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Mounting tabs are welded into the back corners.At this point I'm not wanting to cause any distortion once I've straightened the frame.  The joint is preheated, then welded.  The preheat causes some expansion prior to welding, and slows cooling.  The welds are stopped short of the edges of the tabs to further eliminate chances of distortion, anyways this is the way I figure it   (I don't have a restrained joint where the two pieces meet at the outside corner, this is up for debate though  )Tabs are flush with the back.And finally a piece of sheet metal is placed on the frame to check for distortion.  No distortion.  So the welding techniques maybe worked out good, debate closed for me anyways   Next step is to fit the frame to the trailer.  It's easier to do prior to attaching the skin, cause I'm weak and wimpy and don't wanna lift a ton to mark some holes "Any day above ground is a good day"http://www.farmersamm.com/
Reply:you mean you haven't designed and built a lifting attachment for the tractor yet?There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:You going to completely weld each length of steel that forms the outer skin or are you going to use intermittent welds and caulk the thing?Miller Performance AD Helmet - Camo Edition Soon to have: Jackson HSL 100 - Forest Digi CamoMiller Thunderbolt AC/DC((Currently at welding school))
Reply:Originally Posted by LightsYou going to completely weld each length of steel that forms the outer skin or are you going to use intermittent welds and caulk the thing?
Reply:IMO farmersamm, you are not an idiot... you are one heck of an entertaining character.  Not only that your posts are interesting and I learn a lot - example: this whole warping/bending with heat thing.  I also laugh a lot reading your threads... wait maybe  it's the dog that's funny? Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Originally Posted by DanD78Watch the flash burn on your helper.  Give her a lid and have her move closer.Dan
Reply:ok, now you got me thinkin, Why are you so concerned about warping if you're not concerned about getting her water tight?There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Originally Posted by ThorsHammerok, now you got me thinkin, Why are you so concerned about warping if you're not concerned about getting her water tight?
Reply:Farmersam, looks awesome!  I noticed that in the first picture, it looks like you have a Lincoln stick welder in the photo (opposite side of the sun goddess).  Did you use a stick welder on some of the welds?  If so, how'd the welds come out in your opinion.  In a later picture, I see you have what looks like a Hobart welder.  What model Hobart did you use when flux core welding.  I'm just curious.  I always love to read the "horsepower" that was used for everyone's projects.  I wish more people would post that stuff.  Thanks.Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:I like to build from the vehicle out.  You never know if anything is square or flat.The uprights on the headache rack have been thru a bit of use   Bowed and bentTacked some scrap onto the headache rack, then set a straight piece to line up and offset the box mounts.  They're proud of the rack by about 1/8", shims will be added later to fully isolate the box.  The mounts were clamped to the straightedge and welded to the headache rack, all nicely lined up and square.I thought I'd try out the Plasmatron for punching holes.  It works real good   Considering it's a 3/8" hole it's not too bad.  Close enough for government work.  The hole was finished with a die grinder and a carbide burr.I'm beginning to really like the extra bit of help the plasma brings to the table.  The real beauty is there's no preheat, just pull the trigger and cut.So, anyhow, it's ready for the skin."Any day above ground is a good day"http://www.farmersamm.com/
Reply:All the mounts are installed (prior pic just showed top mounts)I have limited room between truck and trailer, and I wanted the box to be easily accessable from the catwalk between the frame rails without having to lean back or forward.  I will have even less room when pulling the trailer with the single axle.For SuperArc..........I use a Hobart Handler 135 for flux core wire, and the Lincoln for anything 11ga and above.  I love both welders, they've been real good to me, and are on the low end of the cost curve."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Samm, try using a large washer as a circle template with the plasma. Especially on thin stock with faster than you are comfortable with travel speeds. You can make some super nice holes that would take forever to cut with saws or mills.I plasma'd all the holes for the lights on that little utility trailer with a jig made of 3/8" plywood. Easy breezy!
Reply:Originally Posted by daddySamm, try using a large washer as a circle template with the plasma. Especially on thin stock with faster than you are comfortable with travel speeds. You can make some super nice holes that would take forever to cut with saws or mills.I plasma'd all the holes for the lights on that little utility trailer with a jig made of 3/8" plywood. Easy breezy!
Reply:Holes for clearance lights I found the right size washer tack it on and cutting awayMillermatic 252millermatic 175miller 300 Thunderboltlincoln ranger 250smith torcheslots of bfh'sIf it dont fit get a bigger hammer
Reply:Never thought of using washers as a template.  CoolOne thing I've noticed about the plasma column.......it will seek uncut metal.  The arc, if it is indeed an arc, will stray over to any uncut material.  I'm finding that minimal standoff is the best way to prevent this.  I believe a person shouldn't really touch one of these machines till they've mastered the art of cutting with an acetylene torch.  Constant minimal standoff is key to success.  Further the tip is from the metal, the more it will stray."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Well, finished the crazy thing today   Don't have time to post a bunch of pics of the build, but before I get outta here I thought I'd put up some plasma basics I've sorta discovered (works for me anyhow  )For straightedge cutting.................Set your standoff religiously.  Any gage will work as long as it's the right thickness.  I happen to use a 1/8" welding rod.To avoid this And get this You need to do this.........  The reason for the undercut in the path of the torch is because the torch stopped/paused.  This can happen when using a straightedge.  The guide or the metal hangs up the free travel and you get a hiccup.  To prevent this, I've found that smearing some anti spatter goop along the pathway totally prevents any hangups.  And remember to go smooth and steady as for cut speed.  The grease helps.  Just like ball bearings More to follow.................."Any day above ground is a good day"http://www.farmersamm.com/I'm having no water issues because I planned for it when I installed my compressor a while back.There are 3 water traps in the supply piping.  Two in the pipe, and the final trap/filter.The piping is layed out with a riser/condensor dealy.  The extra pipe, and the high loop, allows the water to condense and fall into the traps at the low point at the bottom of each leg.And finally, I'm using a MotorGuard filter at the machine.Hope this helps anybody considering setting up a plasma machine.Project pics later in the day after errands."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Aw Crap........you gotta go back to page 1 for the entire post (twas a 2 post post  )"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Don't sweat the small stuff Sam; this is a great post... especially for folks curious about heat bending and plasma torches! Why am I salivating for a plasma now? Rick V 1 Airco Heliwelder 3A/DDR3 CTC 70/90 amp Stick/Tig Inverters in Parallel1 Lincoln MIG PAK 151 Oxy-Acet
Reply:Got done with my errandsWell, here it is.........The Uranis Model 1999.75 utility box   Ain't a full Model 2000 cause I messed up a couple of things The project turned out mostly fine.Little, or no, distortion Mainly due to very small welds with little chance for distortion.  These welds are more than adequate for the application, you don't need to go biggerThe heat signature lets you know it's a good weldMore to follow"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Here's the screwup WATCH YOUR LAYOUT MARKS I centered the handle on the wrong marks, and had to cut it off and redo it   AND I FORGOT TO NOTCH THE SHEET METAL FOR THE STUPID HINGES PRIOR TO ATTACHING THE SHEET METAL Used a die grinder to score the metal, then fatigued it out (bent it)Oooooomph  Paint will cover it   But I'll know it's there for the rest of my life   (and..........shhhhhhhhh.....it's on the backside)  (well, the handle IS on the front though, CRAP!!!!!!!! )Last edited by farmersamm; 04-23-2012 at 05:48 PM."Any day above ground is a good day"http://www.farmersamm.com/
Reply:And lastly.  I kept the welds to a minimum on the hinges.  You don't need to weld it all the way around, it just adds to possible warping of the lid (1/8" diamond plate)Now I think I'll go soak my head in the toilet "Any day above ground is a good day"http://www.farmersamm.com/
Reply:Nothin' like a good soak in a toilet! 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
Reply:Suppose ought to paint it up and get it on the highway Prep work   I hate prep work!! "Any day above ground is a good day"http://www.farmersamm.com/
Reply:Sambo, those pictures of the Uranus shipping container shop reminded me...you EVER get around to working on that lathe of yours??Lincoln PrecisionTig 275Miller 251Miller DialArc 250Bridgeport millHossfeld bender & diesLogan shaperJet 14 X 40 latheSouth Bend 9" 'C'Hypertherm 900Ellis 3000 band saw21"Royersford ExcelsiorTwo shops, still too many tools.
Reply:Probably everyone is just about sick of this, but Got it mounted up today, with a little help.Kelly suggested shelf liner stuff (sorta rubbery) to keep everything from slamming up and down on the floor.It holds all it needs to hold.  9 4" straps, 2 2" straps, 7 winches, winch bar, gallon of oil, two gallons of antifreeze, and a quart of 90w.  Still some room for a bit more.The box is isolated from the headache rack by spacers (1/4") to keep it from excessive racking during flexing of the trailer.So anyhow, it's in place.And it doesn't stand out very much (stealth mode  )"Any day above ground is a good day"http://www.farmersamm.com/
Reply:nicely done, your posts are always a learning experience Do not argue with an idiot. He will drag you down to his level and beat you with experience.