Televised weld failure

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Was just watching American Craftsmen where they made a big ol wood boat and put it on a fairly heavy duty trailer.  Down the road she goes and they break an axle,  maybe 4" box tube with little mig welds standing way up on top of the joint.  You can see the weld didn't even stick to one of the sides, it looks like you could reach down and pick the weld off the tube with your hand.  Amazing
Reply:That's why the old pro's on here advise the weekend warriors who go out and buy a 110 to 135 amp mig that they just can't build everything their heart desires w/ it.                                     JMHO,                                                 MikeOl' Stonebreaker  "Experience is the name everyone gives to their mistakes"Hobart G-213 portableMiller 175 migMiller thunderbolt ac/dc stick Victor O/A setupMakita chop saw
Reply:You beat me to it.  Can you believe the weld job on that axle stretch?!  It's no wonder they didn't mention the name (unless I missed it) of the "custom trailer" builder.I'd love to hear their excuses for the failure.Last edited by duaneb55; 03-20-2011 at 03:11 PM.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:Originally Posted by mla2ofusThat's why the old pro's on here advise the weekend warriors who go out and buy a 110 to 135 amp mig that they just can't build everything their heart desires w/ it.                                     JMHO,                                                 Mike
Reply:When they pulled the boat out of the shop, you could see the name on the trailer, but I can't remember it
Reply:Originally Posted by Broccoli1or buy a 240v machine and try the same thing iffin' ya don't know what you are doing
Reply:Ooooo, I think I saw that episode a while ago!They hand made a custom wooden power boat, finally get the engines running (twin F-I Mercs, IIRC)  do the check-out run at the shop's marina/lake, and just need to get the boat to the customer (several hours away by road) for final delivery/launch/christening and the trailer breaks apart on the highway.  At speed.  Sparks aplenty!!!!IIRC, They ended up putting the whole boat and trailer on a flatbed trailer and had it trucked (tractor-trailer 18-wheeler truck) to the customer's marina for the launch and christening ceremony.IIRC, bad welds and under-designed material on the axle parts.  The best laid schemes ... Gang oft agley ...
Reply:Happens around minute 37.I can remember in the 7th grade my mom said "people will offer you drugs" by the 10th grade I was like, "where the hell are these people?"
Reply:That is one amazing boat looking boat.   i would have been really pissed if that happened to me.  Whoever put that axle together probably did not have much experience.    i've taught a  lot of guys the basics of welding.   Just because a weld has a nice look doesnt mean there's any penetration.   Dont be scared to turn up the heat a little when mig welding.    Oscillate a little and move the heat around.i wonder with a little tlc if my boat can look like that one.    Attached Images“I'm going to do the thing that God put Galen Beasley on this Earth to do:Have Salon quality hair and weld.Nothing like a good cup of coffee and the smell of 6010 burning in the morning. 971-204-3444 cell API ASME Structural NDT and Repair
Reply:"Craftsman" and that trailer don't belong in the same sentence.Leo
Reply:Guys,    at 38.06 in the above video....its clear that the weld itself didnt fail......but it looks as if the person who welded it together, MISSED the weld lines center.  The break is uniform all the way around the tube....and its square to the axis....like thats where it was cut.  Too me, it looks as if the welder missed his mark by about  1/8" to the right as you look at it in the video.  Anyone else see that?the weld itself isnt cracked, nor do I see signs of it failing.....what I see is a poor welders skill and a miss on the weld seam.BTW.....I was taught / told.....never section an axle......1 pc from shackle to shackle.   Im sure you can use gussets and plates to reinforce the welds....but none were used here.In any instance....total failure on the welders part.JdLincoln IdealArc 250 AC/DC  w/ tigLincoln Ranger 8Miller Millermatic 140Victor Cutting setForney gas welding setMilwaukee power-tools3 legged dog named SpeedyFridge full of Diet Coke1 angry wife2 loud kids
Reply:that boat is beautiful!
Reply:Did you catch at 39.00 min the guy in the grey shirt with the black stripe, trying to put the point of the hook thru the center of a chain link! These guys just don't have a clue. He needed a grab hook not a slip hook."Where's Stick man????????" - 7A749"SHHHHHH!! I sent him over to snag that MIC-4 while tbone wasn't looking!" - duaneb55"I have bought a few of Tbone's things unlike Stick-Man who helps himself" - TozziWelding"Stick-man"
Reply:Y I saw that too. Im surprised that hook stayed on!
Reply:Originally Posted by galencwiThat is one amazing boat looking boat.   i would have been really pissed if that happened to me.  Whoever put that axle together probably did not have much experience.    i've taught a  lot of guys the basics of welding.   Just because a weld has a nice look doesnt mean there's any penetration.   Dont be scared to turn up the heat a little when mig welding.    Oscillate a little and move the heat around.i wonder with a little tlc if my boat can look like that one.
Reply:Originally Posted by Stick-manDid you catch at 39.00 min the guy in the grey shirt with the black stripe, trying to put the point of the hook thru the center of a chain link! These guys just don't have a clue. He needed a grab hook not a slip hook.
Reply:Originally Posted by oxygen454Y I saw that too. Im surprised that hook stayed on!
Reply:Originally Posted by darthwelderGuys,    at 38.06 in the above video....its clear that the weld itself didnt fail......but it looks as if the person who welded it together, MISSED the weld lines center.  The break is uniform all the way around the tube....and its square to the axis....like thats where it was cut.  Too me, it looks as if the welder missed his mark by about  1/8" to the right as you look at it in the video.  Anyone else see that?the weld itself isnt cracked, nor do I see signs of it failing.....what I see is a poor welders skill and a miss on the weld seam.BTW.....I was taught / told.....never section an axle......1 pc from shackle to shackle.   Im sure you can use gussets and plates to reinforce the welds....but none were used here.In any instance....total failure on the welders part.Jd
Reply:It looked like there was two splices in that axle, looks like someone cut the HSS too short and simply spliced in a short piece to make up the difference!However it is possible to splice together a piece of HSS and make it sound, I do it all the time!The trick here is to use proper procedure! When we splice HSS (Hollow structural section such as square tubing or pipe) we insert a smaller piece of the same shape inside the one we are splicing making sure it is a good snug fit. Then depending on the thickness of the original, a single or double bevel weld prep may be required! In this case the tubing used looks like it maybe only 1/8 thick so a simple 1/8 gap should be sufficient. No matter what the thickness is, an appropriate gap is a must!Then when you weld the splice the weld prep and gap combo will result in the weld penetrating into the smaller piece as well as fusing into the outer piece effectively making a complete penetration weld!One other note I should mention is in this case I would have cut the smaller inside piece of tubing no shorter than 8 inches long so as to have 4 inches on either side of the splice. This effectively makes a doubler adding even more strength to the splice. Since this axle had two splices in it then cut a piece long enough to still have the 4 inch extension past each splice!PS: Upon looking at the video again it looks like the HSS used for the axle maybe 1/4 inch think square tubing so I would recomend a 30 to 45 degree single bevel with a 1/8 inch gap!Last edited by katana1150; 08-12-2011 at 06:39 PM.
Reply:Originally Posted by Stick-manDid you catch at 39.00 min the guy in the grey shirt with the black stripe, trying to put the point of the hook thru the center of a chain link! These guys just don't have a clue. He needed a grab hook not a slip hook.