Oil Cooler housing.

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1/8" sheet, I have to assemble the parts that attach to the fittings.  The parts are here,The bottom one is the real thing for a mock up so I can get things in the right place.  My job is to make these look like those and fit on the cooler supplied.  1/8" mild steel I have to look closer to see if its hot rolled or cold rolled.  I used a flap wheel to clean it up but couldn't really tell if there was mill scale or not.  It had been sort of sand blasted.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Alignment plugs in place and I can move them with my hand.This fitting gets welded in the top.  It has a hole and a flange.   Assembled but not  there yet.   Customer will be over in the morning.  Nothing but tig tacks today. Not liking the fitupWater cooled #18 flex head  torch, #6 cup, 15 cfh,  3/32 red or black, 3/32 E70S-6 filler.  Max 150 amps.DavidLast edited by David R; 12-14-2011 at 08:49 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:That wasn't you that did the modifications on the Niagara heat exchangers was it?  This appears to all be EMD (Electromotive Diesel) stuff.
Reply:Originally Posted by 76GMC1500That wasn't you that did the modifications on the Niagara heat exchangers was it?  This appears to all be EMD (Electromotive Diesel) stuff.
Reply:Today I Tig welded from 7:30 to 5.  First time ever.  It was a good day.  I welded the two ends on the 2 units then worked on locating the last hole.  I cut it out freehand.  Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I will get good at this.  They pick up these and leave 3 more.  1" to 1/8" mostly fillet.  Machine set on 200 amps.  I used it all  especially welding the 1" to 1".   Water cooler never got over room temp.  I did not build those boxes, I just put the 3 flanges on hopefully in the right place.  These are marine use.  DavidLast edited by David R; 12-15-2011 at 07:21 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I run a few EMD engines.  We work through a company, MSI who upgrades our EMD engines to meet marine emissions standards (much more lenient than railroad).  I think Young Touchstone was the OEM for EMD aftercoolers and Niagara is the aftermarket option.  I had 4 EMD powered boats though we just sold one.  The oil cooler you just built is standard for packaged EMD engines which are common in railroad applications but I had one boat that used the same box.  Marine EMD engines usually have a shell and tube heat exchanger as an oil cooler  The Niagara coolers you modified were fascinating to me because what you were really doing was converting a two pass heat exchanger to a 4 pass.  So it's up to us to provide some extra pressure to push more water through the same exchanger to give cooler inlet air temps which equals lower NOx emissions.EMD released the 710 series engine (710 cubic inches per cylinder) in the 80's and for the most part dropped support for the previous 645.  The 645 is capable of meeting most of the emissions and economy standards of the 710 and the aftermarket companies have really stepped forward by providing options that bring the 645 into compliance.  Niagara has been a big part of this.Last edited by 76GMC1500; 12-31-2011 at 02:48 AM.
Reply:I printed your post to show to Niagara cooler.  They called today telling me these had no leaks tested at 5 psi.  Everything fit as far as they know.I started another post, building 11 marine covers.DavidReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Which welder did you use?  Nice clean job.TA Arcmaster 300CM3XMT 304S22P12 suitcase feederX-Treme 12VSOptima pulserTA161SMaxstar 150STLHypertherm PM45OP setupStihl 020AVP, 039, 066 Magnum
Reply:David, What do you mean "will get good"?  Hell you are good!!  Bob