Prep Before Welding...

admin

This post is all about weld preparation...9 times out of 10 when the parts come from the machine shop they are not prepped like you have to have them...There is NO prep at all!I had 2 weldments (Adjustable Bearing Assy's) to put together but like usual they were machined and just put on my bench..No weld prep..No cleaning..No nothing.Oiley...Burrs...Etc. Etc. Etc.So it is all up to YOU to do these things correctly OR ELSE!Going by the print you must determine where the parts go and where weld prep must be done.There is NO weld prep per say on any print so the ball is in your court.Most times there are weld symbols and such but the actual prep is up to you.Now see in pic 1...The bottom plate is much longer than where the top plate goes.So going by the print you "Mock Up" the parts and with your trusty magic marker mark where the top goes then prep accordingly.Grind the side ONLY WHERE YOU NEED on a 45 and then grind the top plate where it goes up against the bottom plate to match.Everywhere there is 2 pieces to weld the prep must be done prior to tacking the parts together.I am just gonna let ya study the pics and you'll "Get It" if you don't know what I mean.Any questions please feel free to ask....If you DO know what I mean then just disregard this post.On with the pics!Next!...zap!Last edited by zapster; 11-18-2013 at 04:35 PM.I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Continued..Well there ya go.I hope someone learned something here because that's what we try to do.Oh Yeah..3/32" Red..Machine on "Kill"...Pedal...040 70S-2 filler.I get all the fun jobs....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:I learned something Zapster!  Thanks!One Question:  Where can I buy those 'zippers' you stick on the metal to hold it together? 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 rick vi learned something zapster!  Thanks!One question:  Where can i buy those 'zippers' you stick on the metal to hold it together?
Reply:I think he is just laying a bunch of dimes over the area to be welded then heats it up! It's fishy that there always seems to be an extra one laying around when the "welding" is done! GravelThe difference between theory and practice is that in theory there is no difference.
Reply:Originally Posted by Rick VI learned something Zapster!  Thanks!One Question:  Where can I buy those 'zippers' you stick on the metal to hold it together?
Reply:Personally I love the ones that I get. "Hey I already tacked it for ya, just need you to weld it."  Great post Zap. If you cant fix it with a hammer, it must be an electrical problem."Boy, everyone starts with a full bag of luck and an empty bag of experience. The trick is to fill the bag of experience before the bag of luck is empty."-Grandad circa 1990ish
Reply:That's awesome work bro
Reply:Are you trying to say prep and fit up are 2/3 of welding ...nice weldsBacked my CATMA over your CARMA oops clusmy me  What would SATAN do ?? Miller Trailblazer 302 AirPakMiller Digital Elite  Optrel Welding HatArcair K4000Suitcase 12RC / 12 VSHypertherm PM-45Rage 3 sawRusty old Truck
Reply:nice write up zap! proper prep seems to be a step most I have met skip......Millermatic 30aMillermatic 210Miller thunderbolt 225 ac/dc/ccMiller HF15-1-wg tigLincoln ranger 10(honda powered)Cebora 175 mig Too damn many tools but oddly not enough......
Reply:Every time I watch someone fab up welding work, I learn something.  Welding is a lot more than melting metal.  Thanks for taking the time to teach.
Reply:(((First let me state : I have no clue what I am talking about and I ask lots of stupid questions and I don't understand all the abbreviate terms yet.)))That's a beautiful weld... I am guessing its TIG ? Can you get the same dime effect with Mig? Also do you grind the edge at that angle because its a thicker material and you want to insure penetration and also a flat weld? Would you also do the same 45 edge on for example welding two pieces of 2x2inch 11gauge square tubing together? Or on thinner materials it's not needed ? Thanks for taking the time to post the pics and help out!
Reply:Originally Posted by Ramsey(((First let me state : I have no clue what I am talking about and I ask lots of stupid questions and I don't understand all the abbreviate terms yet.)))That's a beautiful weld... I am guessing its TIG ? Can you get the same dime effect with Mig? Also do you grind the edge at that angle because its a thicker material and you want to insure penetration and also a flat weld? Would you also do the same 45 edge on for example welding two pieces of 2x2inch 11gauge square tubing together? Or on thinner materials it's not needed ? Thanks for taking the time to post the pics and help out!
Reply:If done whilst Harboring Fright ? Attached ImagesBubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:Those are the cheap import dimes aren't they?   .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:Zap,nice lookin work sir!Why .040 wire?
Reply:Originally Posted by vwguy3Zap,nice lookin work sir!Why .040 wire?
Reply:OK here we go with another one that needed MAJOR prep work done...These are some of the print pics..Parts to prep..Next!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:First thing to do after looking over the prints is to mock the piece and measure approx. where things go..Now mark where you must remove all the millscale....Get grinding!!!Next!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:OK now don't forget the prep on the inside piece..Note the bevel on the end..Do both sides on both ends..Print says 26" NOT 26 1/8"Grind and massage inside part until it fits..Uggghhhhhh...Lots to fill in after...Remember I didn't make the parts but I have to deal with them...Next!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:After clamping where needed tack the top on both sides then CAREFULLY flip it over..Re-measure and tack the bottom..Finish weld both sides top and bottom..Remember all that space to fill in?Not bad!Now to do the other side..OK now that's done..Next!...zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Good stuff Zapp. My kinda work. I only weld because it's how you stick metal together. I looooooove to build.I was getting ready to go off on a Ray Charles-Stevie Wonder rant  until I saw your disclaimer.Bubble gumTooth pixDuct tapeBlack glueGBMF hammerScrew gun --bad battery (see above)
Reply:Now all that's left is flat plate to the channel pieces..Make sure all that scale is gone!Little eyelet..Done and ready for paint!Now remember one thing here..Before you start marking and grinding etc. CLEAN THE PARTS FIRST!!!!All that cutting oil and other funk gets on your fingers/gloves and all you do is get everything covered in it before you know it and that sucks.After grinding and such CLEAN THEM AGAIN!!!!After that you may proceed.I hope someone got something from all this!I get all the fun jobs.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Originally Posted by zapsterFirst thing to do after looking over the prints is to mock the piece...
Reply:Killer job Did that piece warp at all? Seems like it would very easily.Miller Dynasty 200Millermatic 211Instagram?.... find me @ WELD_MEDICOriginally Posted by tig_21Killer job Did that piece warp at all? Seems like it would very easily.
Reply:Originally Posted by zapsterI hope someone got something from all this!I get all the fun jobs.....zap!
Reply:Originally Posted by zapsterI hope someone got something from all this!I get all the fun jobs.....zap!
Reply:nice write up zap on dealing with carbonMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Just nice, great prints ,no one knows how to detail any more!  American Bridge detailed to 1/64  100 years ago  and the dwgs were checked. Our shop the same way ,detail does not grind , wait for the fitters fit and the. welders weld.
Reply:Nice looking work!In regards to fit issues, I feel your pain.  Some days, I can't believe how many times I have to go back to the machinists and ask them to at least make their own parts fit together.  I regularly get entire batches of parts where features that are supposed to insert into one another can't because the peg is too big for the hole, literally!  There are 3 machinists, each with their own machine, running one job at a time, and they still can't figure it out.  These guys have been doing their work for years, and still don't know that they need to remove burs on parts that they flip over - then they wonder why all the parts this time around came out half as thick as last time (this was last week's snafu)!I think they must think there's a fancy setting on my $3500 welder that fixes the mistakes on their $500,000 worth of CNC equipment.It's so nice to come home and work in my own space - ahhhhhhhh control...Miller Dynasty 200 DXMiller CP-300 with 30A feederHypertherm Powermax 900Oxy-fuel w/Harris torchesScotchman Glide-in bandsawMonarch 10EE latheEmi-Mec Autoturn latheDeckel FP2NC milling machinePro-Tools 105 Bender
Reply:Thanks everyone! You guys keep in mind that YOU are the last one to touch this so your IT.It's your azz so take the time and do it RIGHT!I don't know if that 1/8" is really important BUT if the frame has to fit somewhere and it don't?Do you have any idea how hard it would be to take this apart without ruining it? It's all these little things that add up to the big picture....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:When welding smaller/thinner materials constantly be aware of heat distribution. Using .035 solid core wire to weld intermittent 1 inch beads will most likely not warp your assembly. However, I deal with with .045 metal core on a daily basis and if not tacked properly and welded a certain way it'll be warped to ****.Sent from under a Miller welding helmet
Reply:Very nice work zap!! That cope that was cut by someone else is a very common mistake when fitting channel together. You forget that the channel has a bevel to it, and boom you have a nice big gap. I learned this years ago when I first started coping channel because I made the same mistake.Ya gotta spend money to make money!
Reply:I hope the person drafting your prints is better at design than he/she is at weld symbols.
Reply:Originally Posted by zapsterThat was all I had left until my L.W.S. opened this A.M....zap!
Reply:Originally Posted by zapsterNo..not at all!There is a trick to keeping things straight also......zap!
Reply:Originally Posted by welderShaneWhat is that trick? Clamp a round rod underneath the joint your welding to put pressure on it so when it pulls it will pull back straight?
Reply:Strategically placed tacks, over compensating on angles, and knowing how, where, why, and how much everything wants to pull and go where it wants to go through experience will tell you. For example. Tack up two pieces on a 90, and see how it's not 90 anymore. Then make a full pass on it and see where that winds up. Now, do the same routine and over compensate, and see how it winds up. Do this a million times and it starts to sink in after a while. Great job zap! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Art work in its own right!Learned a few things myself.Thank you.From the desk of Kevin CaronTrying to be the best me I can!www.kevincaron.comAHP Alpha Tig 200x MillerMatic 251Miller Syncrowave 200
Reply:inspiring work
Reply:Originally Posted by weldermikeStrategically placed tacks, over compensating on angles, and knowing how, where, why, and how much everything wants to pull and go where it wants to go through experience will tell you. For example. Tack up two pieces on a 90, and see how it's not 90 anymore. Then make a full pass on it and see where that winds up. Now, do the same routine and over compensate, and see how it winds up. Do this a million times and it starts to sink in after a while. Great job zap!