Help filling holes!

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I am 2 days into what should have been a 2 day job, but looks like it will be four days.  This is a horse fence.  The top rail and and posts are drill stem, and the 3 rails are 3/4" rod.  When I took over the job from the other welder (he gathered his stuff and quit 1/2 way through the final draw) all that was left was to weld the holes on the top and bottom 3/4 rod where it goes into the post.  Here's the trouble.  In the posts along the driveway, he drilled the holes and the rod fits snug and will make a nice easy weld.  The other 1800 ft he cut with a torch with no regard to the size.  My problem is that I have to fill these holes.  For the other parts, I have been using 3/32" 6011 @75amps and is working nicely.  What is the best way to fill these holes quickly but still look good. Attached Images
Reply:Here are some more.  If you look carefully you can see the run of fence. Attached Images
Reply:Then, after I get the fence done, I get to start on a fence between these columns and gates.  After that is an extension of the barn. Attached Images
Reply:more gap than id try to fill with 6010..ifyou can find some pipe  with the same id as the od of the posts maybe cut patches and drill 3/4 holes in them....?
Reply:are you using arc stick welder? i had to fill a few holes in H beams before and cut up loads of little bits of flat, and any scraps of metal i had around the shop even on old bucket of 6 inch nails got the chop, and placed them into the holes and gaps as filler, and then welded the whole lot over. not sure if it would be economical time wise though with 1800ft of fence to do. best of luck with the job, at least it looks like the weather is nice.
Reply:Or get some 3/4 pipe and cut pieces about an inch longer than the o/d of the pipe and use 'em like a sleeve over the 3/4" rod....Mike
Reply:Originally Posted by mrmikeyOr get some 3/4 pipe and cut pieces about an inch longer than the o/d of the pipe and use 'em like a sleeve over the 3/4" rod....Mike
Reply:I would explain to the customer that unless he wants it to look like crap then it's gonna take some time which means money.... me personally to make it look right, The 3/4" rods would be cut and removed from the posts.  then I would take pipe and cut out pieces and weld in all the holes and grind them smooth.  Then recut the holes put the rod in and weld in place.  If he wants it done right that's one thing.  If he just wants the rods stuck and the holes filled in that's another.  Remember, YOU took the job on, so now it's YOUR NAME on the job.  Good or bad.  I'd want it done right if it was me.I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:Why not a piece of pipe the same size as the post, split lengthwise, then drill your hole in the split post.  Remove the rails, lay the split pipe over the hole & weld it on.  Re-run your rail through the holes.Use the split pipe with the correct sized holes as a patch on either side.  It will look a lot better & reinforce the post at the same time.Or remove the rails, drill out the holes the same size & let the rails "float" in the posts.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Dont know if you have a press, but what I would do is punch out round blanks with a 13/16" hole in the middle.  Form them with the press so they fit the pipe, slide them on the rod and weld.   You want it to look good, but its also just a horse fence that hardly anyone will ever look at close enough to see whats going on there. Talk with the homeowner and see what he wants to do, there a plenty of ways to do this but the only right one is the one he likes.Have we all gone mad?
Reply:. . .and he did this to every post for all three rails??!!  He should be shot.I agree with sn0border88 on the suggestion AND to talk with the homeowner, share the options and see what he/she likes.  To keep from pulling all the rails you could cut the formed donut 'patches' in half weld them back together in the process.As hammack points out - it's YOUR name on the line now and if you share the options (and related costs), do what the owner decides they want you to do to fix the other guys mess and follow through you should be in good shape.  Just make sure you do your math correctly to get your costs right.  That's alot of patches if he did that to every one.  Good luck and keep us posted.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:If you get to weld these in place, without making any of the dozens of patches suggested by others, I'd break out your 110V MIG/FCAW machine.  You could fill all those with 6010, but it would take you a looonnnnngggg time.  But some small diameter MIG wire and a wind screen to protect your shielding gas would get the job done.   The clean up with MIG would be minimal, unless the welds needed to be ground flush.  Like others have said, it'll never be pretty unless you patch those holes or grind all the weld metal you put down flush.Were I doing this job, I'd price the work such that I could afford to buy a small mig machine to get the job done...if I didn't already have one...Nothing like being stuck between a rock and a hard place.  If the owner wants a cheap solution, I'd scratch that job off your list of references for future clients.  Nobody will look favorably on the job if it gets done fast and dirty, no matter how much you tried to explain...Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Good suggestions from everyone, thanks.Roco:  The weather is "pretty" but that's about it.  95 degrees, 85% humidity, no wind.  Welcome to Mississippi.  Just wait till August!  Welcome to my Hell.Duane:  At least he made the rails along the driveway nice and snug.  The previous welder set it up so that he would get 3 equal draws along time.  He got half way through the last draw and split.The owner really doesn't want to put any more mony in it, like you guys said, it's just a horse fence.  He wants the rails along the driveway to be nice and pretty at least.  That is where friends, family, and visitors will walk to to see the horses.  On the very back side by the tree line it got really nasty.  Some of the holes where 1 1/2" round.  He's going to sand blast and paint white when done.
Reply:Originally Posted by A_DAB_will_doIf you get to weld these in place, without making any of the dozens of patches suggested by others, I'd break out your 110V MIG/FCAW machine.  You could fill all those with 6010, but it would take you a looonnnnngggg time.  But some small diameter MIG wire and a wind screen to protect your shielding gas would get the job done.   The clean up with MIG would be minimal, unless the welds needed to be ground flush.  Like others have said, it'll never be pretty unless you patch those holes or grind all the weld metal you put down flush.Were I doing this job, I'd price the work such that I could afford to buy a small mig machine to get the job done...if I didn't already have one...Nothing like being stuck between a rock and a hard place.  If the owner wants a cheap solution, I'd scratch that job off your list of references for future clients.  Nobody will look favorably on the job if it gets done fast and dirty, no matter how much you tried to explain...
Reply:I would just fab up some patches to cover the holes already put in the posts.  Never thought about the press & a punch....because I don't have a press yet.  I do have plans to build one though.As to making the patch, a punch press could make the hole, then a press brake to make it round.  Would only have to be about 1.5" wide too & 1/8" thick.  Make up enough of them or teach the kids how to whack these out at home, then go weld em in.  Quick & easy.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:i thank i would use washers there should be some that would fit the sucker rod and still make the patch just my 2 cents i hope this helps
Reply:The washer idea is not bad at all, but you are still gonna have to pull the rods.  If i am figuring right and you have 1800ft of fence with holes cut like that as you said that means you probably have close to 1000 welds to make on that crappy a fit up.  If you are already loosing money then you may be best to walk if he doesn't want to come off of more money to fix the problem.  I can guarantee that he isn't going to get anyone else who is worth his salt to do the job for what you are charging him.  Did you give him a total cost or a by the hour price?  If it's by the hour then get a wire machine and start welding them up.  If it's total cost then go talk to him and if he is not willing to put in extra to correctly solve the problem then walk.  You are on the losing end here.  Finishing a job where the first guys work will look good, and yours will look like crap because of what the first guy did, and losing money on it to boot.  Good luck...I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......
Reply:What if you split the washers in half then weld each half  around the rod ?
Reply:Anyway you fix this one you're hosed if you set a price. Always walk all the way through a job. If another guy pack his stuff and left he did so for a reason. Never take over another job for a set price. 95% of the time there is a surprise waiting for you. Be sure to call Dig Rite or whatever it's call there before setting any pole not already set. The first guy may not have done so or the owner may have added stuff sense the area has been checked.Tough as nails and damn near as smart
Reply:If all the holes are about the same size you might check for some pipe that will fit over the rod and in the hole. This might fill it up enough to weld  over and then grind it to look good. It would be like a sleeve around the rod stuck in the pipe.
Reply:I see after reading the post again Mike had the sleeve ideal first.
Reply:I meant to tell you, I like that horse. He has a good neck on him. I can see why the owner would want a good fence.
Reply:I don't know a thing about horses, in fact, I am kind of scared of them.  They kept walking over to see what we were doing.
Reply:I think the washers are probably the fastest way to do it.  Hard to find un galvanized washers though.  You said the guy's gonna sandblast it anyhow.  Washers will be easier to work with when pulling the sucker rod.  They'll not try to wedge in the holes.If the guy wants to get fancy, probably can afford it by the looks of the house........Take some of the leftover pipe, make pie cuts around the dia of the pipe, cut the right size hole, and you have a pretty nice looking/fitting fix.  It's the same principle as washers, but might look better.  It's a ton of work though, but so's trying to fill the gaps with any kind of filler wire or rod. Attached Images"Any day above ground is a good day"http://www.farmersamm.com/
Reply:A horse may wait 5yrs to get you, but they will eventually.  Very patient animalsI'm more comfortable around cows.  They seem more predictable."Any day above ground is a good day"http://www.farmersamm.com/I mean for the new patches to just be welded onto the post, not cutting the post out to accept the patch."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by farmersammA horse may wait 5yrs to get you, but they will eventually.  Very patient animalsI'm more comfortable around cows.  They seem more predictable.
Reply:The thing to remember if you are working around the horse is not to walk up behind him and startle him. Their usual reaction is to kick, even a good horse. All you have to do is say something just to let him know you are there. I feel sure he is a gentle horse. If he was an outlaw you would be able to see all his ribs and they wouldn't be spending the money on a nice fense like that.
Reply:They have 18 horses, a few pregnant ones, and a few that they are re-habing.  I'm not planning to get close enough to one for it to kick me.
Reply:looks like you have alot of work ahead! its either going to cost time or money. time you cant recoup, money you can! i agree with the washer idea, try calling some of the tracktor supply stores and look for bucket shims. the ones that go in between the ears of the bucket where it meets the stick on a backhoe or excavator. thin enough to bend into pipe dia. by hitting with ball peen hammer on a block of wood. will save lots of time and will look like a reinforcment ring when done.
Reply:I don't know a thing about horses, in fact, I am kind of scared of them. They kept walking over to see what we were doing.
Reply:Originally Posted by fredfYou might suggest to the owner to keep horses away so they don't get flashed. . .
Reply:That's why they're dangerousPlus they got top, and bottom teeth.  Plays hell with a pasture"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Drill holes in the next size up pipe, maybe 3" long sections.   Cut them in half, thru the holes.  Place half on each side, make a few decent tack welds, you are done.  No reason to weld all around.  Don't weld the sucker rod to the post or the patch.Or cut washers in half, tack, hammer them around to fit, tack again.  May look better.  Either way, fast and cheap.
Reply:They have 18 horses, a few pregnant ones, and a few that they are re-habing. I'm not planning to get close enough to one for it to kick me.
Reply:Originally Posted by 6010If they can afford to feed this many horses, they can afford to pay you to do the job right
Reply:Went to Home Depot and bought 2 rolls of rebar wire.  Had my helper wrap the ends near the holes.  This way I had something other than air to fill.  Worked like a champ.  Wish I had done this on the first day.  Would have been done in the two days I originally thought.  Thanks for all the advice.
Reply:Glad that everything is working out okay, and sorry you got screwed by the previous guy on the job.Charge the guy what the job was worth, like Pookie (POOKIE????) said.  If the owner doesn't want to fork over the money, leave the gate open and let all his prized horses out!
Reply:Originally Posted by JC'sWeldingThey have 18 horses, a few pregnant ones, and a few that they are re-habing.  I'm not planning to get close enough to one for it to kick me.
Reply:Originally Posted by farmersammA horse may wait 5yrs to get you, but they will eventually.  Very patient animalsI'm more comfortable around cows.  They seem more predictable.
Reply:How did it turn out?  Pics?I'm a Lover, Fighter, Wild horse Rider, and a pretty good welding man......