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I mentioned this job in another thread last week so here are the pics...(The thread about the guy whining about grinding...)But anyway..This is the job.As mentioned in the other thread there are 1750 pieces to this job..5 in each assy..All prepped by ME..All welded by ME.Customer DEMANDS tig because the other vendors have migged them and stick welded them and they have failed in operation..(I saw the sample they sent us first..Now I know why)This is our first attempt at this job and the samples passed inspection..I have one month to do this along with all the other misc welding and lathe stuff to do..Started beginning of this month and have 125 out the door so far..Can you say REDUNDANT?.Oh well...Here we go...# 1.. Channel and customer supplied jig..# 2.. Grind both ends like this..# 3.. Grind bottom of "T" in this area..Note 2 sizes..one for each end..# 4.. Grind all around on sides...Basically grind everywhere the "T" meets the channel and weld all around..# 5.. Clamp in position..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:r u allowed to weld the end of the channel tothe back of the tee?
Reply:As we continue..#1..Tack the "T" in 2 places on the front and both ends of the channel..#2..Remove from jig..Place upside down..Clamp and weld the bottom..Both ends..#3..Flip over and weld across the front first then down the sides...Both ends...#4..Welded...#5..Welded...Continued.....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:What and you're not even whining about all the grinding that should be beneath you at your pay grade???   lmao. Not trying to stir up sh%$ but the grinding looks like it adds a lot of time to the project, have you seen the Pferd Poli-fan wheels? They are a flap type 5" disc made for cleaning out radiused corners. You seem to have things under control but those would fit the radius of the channel perfect. I use them to clean up welds on the bead retainer of aluminum wheels when they crack. Hell anything that would save one minute on each one those would add up to a lot of time saved. Attached Images "Anybody can talk $h!t behind a monitor, I let the quality of my work speak for itself"Lincoln Square Wave 255 and 355 Tig Lincoln 255 Power-Mig w/ spool gun Koike 5 x 10 CNC plasma Hyd-Mech DM-10 bandsaw Ineco QB-76 NC tube bender
Reply:OK now that both ends are done...#1.. Put MY fixture against the end of the channel...#2.. Add angle piece as seen..#3.. I just tack the left side closest to me while it's in the fixture then remove the fixture..#4..Tack the opposite end in the front then the other side front then the rear that is not tacked..#5.. Weld side facing you..(Kinda looks like tig like mig)Gasp..One more.....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:As we come to a close...#1..Now we just take the channel and place it on it's side and do the other side of the angle..#2.. Complete end..#3..Tungsten stick out...Note..NO GAS LENS!!!Gas lens would have put the torch further away from the inside channel welds down the side of the "T"...#5 cup..3/32 Red..Welder on KILL...1/16" 70S-2 filler..I have 3 more pallets of channels staring me in the face..A 55 gallon barrel full of angle pieces and a pallet of "T" pieces all neatly stacked ready for prep..Oh joy.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 Mick120I agree with Coupe....flap discs are all I use, quick and easy.I still don't understand why mig wouldn't work on those....if done correctly of course.
Reply:you really do get all the fun jobs. only 225 completed units to go.what's the whole unit look like, and what is it for?There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Originally Posted by ThorsHammeryou really do get all the fun jobs. only 225 completed units to go.what's the whole unit look like, and what is it for?
Reply:Originally Posted by CoupebuilderWhat and you're not even whining about all the grinding that should be beneath you at your pay grade???   lmao. Not trying to stir up sh%$ but the grinding looks like it adds a lot of time to the project
Reply:Wow, sucks to be you. But a buck is a buck! To bad you couldn't give him a sample one that's MIG'd for him to try. He'd see what it should perform like. But at the same time you can't blame him if he's been burned a few times before. I'm betting they'd be half the cost if you could MIG them. But again, the buck's are going into your pocket. Have you a pic of the ones that broke?200amp Air Liquide MIG, Hypertherm Plasma, Harris torches, Optrel helmet, Makita angle grinders, Pre-China Delta chop saw and belt sander, Miller leathers, shop made jigs etc, North- welders backpack.
Reply:Don't you just love the people in charge of designing parts?
Reply:Originally Posted by bert the welderWow, sucks to be you. But a buck is a buck! To bad you couldn't give him a sample one that's MIG'd for him to try. He'd see what it should perform like. But at the same time you can't blame him if he's been burned a few times before. I'm betting they'd be half the cost if you could MIG them. But again, the buck's are going into your pocket. Have you a pic of the ones that broke?
Reply:I saw the "sample" one yours look much betterDisclaimer; "I am just an a$$hole welder, don't take it personally ."
Reply:Originally Posted by zapsterWe only have a 110 Mig and that's not gonna cut it..Customer demands tig and a hard wheel will outlast the flap disc wheel by far on this..I have both...No contest....zap!
Reply:Originally Posted by weldbeadr u allowed to weld the end of the channel tothe back of the tee?
Reply:Nice job , give the customer what he wants , a good job shop project , money in the bank !!!
Reply:Customer wants to spend money. TIG looks great. Do not disagree with customer.
Reply:Originally Posted by MikeGyverI think doing this can actually weaken the joint.How many amps are you running and what size filler?Kinda weird that he wants them TIGd, I'd try to convince the guy the parts should be dual shield welded and get the job done in half the time.
Reply:WoW you get all the good jobsJust think of all the tig practice you will get in...Greatly improving your tig skill and technique You forgot the dimeLOL@ ZAP  Backed 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:Originally Posted by farmallCustomer wants to spend money. TIG looks great. Do not disagree with customer.
Reply:i guess if they wanted to pay for tig you could give it to them but it seems like they are pizzing their money away.   Even with your equipment that looks like a stick weld job if i have ever seen oneVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:What's wih he crater crack on the end of the bead on the back side?Miller bobcat 225g  - spoolmatic 1Mm250 - 30a spoolMiller spectrum 375Thermal arc 95 Everlast Ex 250As the boiler turns, these are the days of our lives
Reply:those definatly could be properly stick welded, even if the part requires a higher strength steel and corresponding electrode to suit. Quite obviously wasnt welded by a welder with adequate skill if a quality "stick" weld broke.
Reply:And with a drumroll...There it is!Assy 350 of 350!!!I thought this job would never end...Done at 8:45 this AM and now it's  time!!!I had no idea that the whole plant these go in was shut down and depending on my tig torch to get back up and running...Well the maintenence department will be at it all weekend getting these in place so they can be up and running Tuesday AM.....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.Great job Zap. and if I recall you're ahead of the deadline, is that correct? I thought you had till the 31st.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Originally Posted by ThorsHammerGreat job Zap. and if I recall you're ahead of the deadline, is that correct? I thought you had till the 31st.
Reply:I hope they got charged for the change in deadline.There are no problems. There are only solutions. It's your duty to determine the right one.Hobart Handler 210Airco 225 Amp MSM Stinger
Reply:Originally Posted by ThorsHammerI hope they got charged for the change in deadline.
Reply:Originally Posted by zapster...Customer DEMANDS tig because the other vendors have migged them and stick welded them and they have failed in operation..(I saw the sample they sent us first..Now I know why)
Reply:Congrats Zap, that's some strong persistence.  Paid work is paid work, but 350 of the same thing, one after another isn't something just anyone can get their mind straight to do.  Nice work.
Reply:Originally Posted by Rick VWhy?Zap, saw your 110 volt MIG response... kind of weird that your shop has no decent power MIG machine.Yep - perfect stick job!Yep - Stick for certain... too bad it was poorly done the first time.
Reply:To whoever said use flapdisks... yes.  It's all I do.  I love flapdisks like I love Zap's welds.I should marry that ****.JoeMiller 140 Autoset (2010)Miller Syncrowave 250 (1996)
Reply:Originally Posted by el bobCongrats Zap, that's some strong persistence.  Paid work is paid work, but 350 of the same thing, one after another isn't something just anyone can get their mind straight to do.  Nice work.
Reply:Originally Posted by zapsterI had no idea that the whole plant these go in was shut down and depending on my tig torch to get back up and running...Well the maintenence department will be at it all weekend getting these in place so they can be up and running Tuesday AM.....zap!
Reply:Originally Posted by astaindsoul5446What's wih he crater crack on the end of the bead on the back side?
Reply:Good job zap, well deserved beer break I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys