Aluminum shelf - take 2...

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Couple weeks ago I did a box and a shelf for a guy who told his boss he could weld alum...but, he couldn't. So it came to me pre-cut.Well, he also measured wrong.  The big shelf was an inch too wide and his boss also decided the diamond plate should go inside like a drawer.3/16" plate, 1/4" anglewp-26, 1/8" 2% thoriated, #8 standard cup1967 Airco at 230 amps (too hot for the torch - but oh well)Use to look like a shelf:Now it looks like a drawer and 1" slimmer.  I trimmed a little from all four edges so the old welds would be gone.The bottom: (I sanded out those old weld marks when done)One of the corners after cutting and welding the second time.The "cutting tool" next post.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:The cutter I used to cut out the welds and bevel the 1/4" angle for welding.Not for the faint of heart but works awesome!Bought a blade from a toe-kick saw and drilled it out to accept a bushing. This let it fit my die grinder I wear a shield and glasses with this setup.  And both hands on the tool so I don't lose any parts I've been using it since last year and it's really fast at zipping out welds.  But I think it's a tad dangerous Last edited by MinnesotaDave; 11-02-2013 at 10:28 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:A tad dangerous to say the least. All it needs is a guard in order to make it somewhat safe. Look at the auto body cutoff tools.
Reply:I have a cutoff tool as well and have studied the issue.  Just have not gotten around to doing anything about it I'm thinking it should clamp on the base so I can loosen and rotate it if the switch is ever in the way.Sort of like how my guard fits on my Dewalt angle grinder.If that does not work, I plan to adapt it to a cutoff tool buy trimming off the existing guard and welding up a modified one.Last edited by MinnesotaDave; 11-02-2013 at 11:30 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:1...2...3...4...5...6...7...8...9...10just making sure I have all my fingers after looking at that thing.by the way nice save.
Reply:Originally Posted by Scott Young1...2...3...4...5...6...7...8...9...10just making sure I have all my fingers after looking at that thing.by the way nice save.
Reply:Cutter reminds me of some of the tools I think Dave posted up for doing prep on his alum boat hulls. I seem to recall some open carbide saw blades there as well for alum prep..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:Yee-haw!  That cutter gets the blood pumping just looking at it!
Reply:I bought a carbide tipped blade like that when I needed to extend the stock external housing for my jetboat. I mounted the blade to a spindle that I chucked up in my drill press, set the table where I needed it, and moved the housing around, and swinging the table as necessary. After cutting and cleaning it up, I bent up some 1/4 x 2 aluminum flat to match the profile, then took it all to work and used the tig machine there. I didn't take any pics during, and only have after pics.
Reply:Originally Posted by DetailerDaveI bought a carbide tipped blade like that when I needed to extend the stock external housing for my jetboat. I mounted the blade to a spindle that I chucked up in my drill press, set the table where I needed it, and moved the housing around, and swinging the table as necessary. After cutting and cleaning it up, I bent up some 1/4 x 2 aluminum flat to match the profile, then took it all to work and used the tig machine there. I didn't take any pics during, and only have after pics.
Reply:take an aluminum test that requires a back gouge and you will find something similar to an angle grinder with a blade.  referred to as a 'suicide saw'.like so,http://iws.onlinesupply.ca/index.php...oduct_id=22122Last edited by ncountyline; 11-03-2013 at 09:30 AM.
Reply:I have a Makita model 4190D battery operated saw that uses blades like that.  Custs really nice!  Essentially a miniature circular saw.  It has a water bottle attachment so I can bleed cooling water onto the blade right at the cut point.  Install a diamond abrasive blade and it will saw through ceramic tile and plate glass.  I have even cut mirrors with it.  Mine is c. 1989, the newer 12V model , SH01W can be had for about 140 bucks.  Cheaper than living with missing digits or other gnarley damage:http://www.factoryauthorizedoutlet.c...rcular-saw-kitMember, AWSLincoln ProMIG 140Lincoln AC TombstoneCraftsman Lathe 12 x 24 c1935Atlas MFC Horizontal MillCraftsman Commercial Lathe 12 x 36 c1970- - - I'll just keep on keepin' on.
Reply:oops.  nice shelf though
Reply:Originally Posted by MinnesotaDaveOpen wheel on the drill press - sounds effective and dangerous - perfect
Reply:This was posted on hear back 2012 there was a video of it in use .Last edited by T E B; 11-03-2013 at 02:17 PM.TO INVENT  YOU NEED A GOOD IMAGINATION  AND A  PILE OF JUNK'' - THOMAS EDISONMost Of The Time People Don't see The Quality of a Good Job Unitl they see a Bad Job !! -Scott Esplin
Reply:Nicer than the last Dave! Good job! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by ncountylinetake an aluminum test that requires a back gouge and you will find something similar to an angle grinder with a blade.  referred to as a 'suicide saw'.like so,http://iws.onlinesupply.ca/index.php...oduct_id=22122
Reply:hahahha you are crazy! BUT you do nice work, i don't know if a thank's for sharing is appropriate..lmao ;o))