My first Welding project.. part 1

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I'm a newbie with a new Tig welder and this is my first welding project.. I've done some practicing on aluminum (watching all those videos from Welding Tips and Tricks), but haven't built anything real yet...I have a "Kirkland" brand SS Barbecue that I bought from Costco several years ago that has gone through two three sets of Cast Iron burners.. I've had enough and decided for my first TIG project I would build some new ones.. (Hey, I like a little challenge...)As you can tell, the Old burners are a bit worn out:I had a friend provide some Schedule 40 316L SS, 1" pipe that I'll used for the burner tubes.. I bought a piece of 2" round 304SS that I'll turn and mill for the Venturi mixing chambers and air valves.  And I bought some 1 x 2" .1" rectangular 304SS for the cross piece..I figure having heavier metal will be easier to weld... that thin stuff just seems too sensitive for a first project.The Parts.. cut but not processed:I turned the mixing chambers on my lathe, milled the slots in the burner tubes and the cross pieces on my mill (I have an Emco Mill Lathe Combo that works fairly well for this task.  I also drilled about 200 little tiny #50 holes (stainless is hard to drill). Had to continuously squirt coolant on the drill:I sliced off some chunks of 1" round 304SS and faced them on the lathe to create the end caps for the burner tubes.. These are the first welds on the project:Ready to weldWelded:Man those are ugly welds..But it grinds up ok :-)Welding the Air Valves onto the mixing Chamber:Welding the feeder tube onto the crossbar.  The welds seem to be getting a little better but still pretty ugly:... More in the second part.
Reply:Continued from part 1...Welding the cross bar to the burner tubes... I think this is a pretty weld :-):Tacking the "U" end onto the burner tubes... Looking good...But.... Wait a minute... what the crap??I welded the dang thing upside down... get out the moto-tool and the cut-off wheel...Ok, first one is all welded.  The welds are not all the pretty, but hey, that's what the flap wheels are for... aren't they?The weld holding the mixing chamber to the feeder tube:All ground and shiny:So what are the top 5 things I learned on the first one??5.  Thicker metal is a whole lot easier to weld than the thin stuff.. sometimes you don't even need filler..4.  Make sure the valve on the argon tank is turned on before you start welding... otherwise just the noise tells you something is wrong...3.  Keep the tungsten sharp.. it makes a hell of a difference in being able to control the arc.2.  When you have parts that fit symmetrically but aren't symmetrical... make sure you examine what you're doing before you start melting the metal.. 1.. And the number one thing I learned on this first one was ... keep your foot away from the pedal when you have the torch resting on your lap... That dang high frequency arc will go through anything to get you your body parts... Willy is still twitching...One to the Second one:One other thing I learned from the first one is "planing". It was really tough welding the cross bar to the burner with the feeder tube already attached (I had about an inch of space to try and squeeze the torch in... and it just didn't go really well.. So this time, I'm welding the cross bar first, then the feeder tube..And here are both burners, finished:So things I learned from the second one:1. Arc Length... The shorter I can keep the arc length, the more control I have and the better the completed weld looks.. I've got a long way to go before I would want to weld something structural, but it's getting easier all the time...  And it helps a lot to have a welder that just seems to work right.2.  I'd like a lighter torch.. the basic torch that comes with the PM256 is a water cooled torch (been using it air cooled) and it works fine, but it seems to be heavy and bulky compared to some other's I've seen.And finally, here are the burners installed and running in the old barbecue... I don't expect to have to replace these for a very long time...
Reply:I would have enjoyed seeing the machine work, and fixturing for machine work and tacking.Machine work is cool in the control, setup, and attention to detail.  Dealing with three dimensions in a very precise way.As you've probably found out, the welding is fast paced, spur of the moment activity.  Many things occuring at the same time, and you have to keep an eye on all of them.  Eventually it becomes almost mechanical as your skills improve.Marriage of the two skills gives a wide range of possibilities.You took the plunge, and it appears that all is well with a functioning unit.The welds will, or won't, get better with time.  It depends on your enthusiasm, and willingness to work at it.  And, I'll be the first to say this, it can also depend on a friendly person taking the time to let you watch how it's done.As little as a few seconds watching someone manipulating a puddle could be all it takes.  I experienced this last Summer.  Litteraly a few seconds viewing someone working.  It took a while to train my hands to do the same, but it did seem to take hold(sorta).  But I had seen it, and it stayed in my "minds eye".Videos might be fine, but person to person contact is better.  Seeing it done properly, in front of your nose leaves you little room for excuses.  Because after the demonstration, the "demonstrator" is looking over your shoulder as you try to do what's just been shown to you.  Pucker time  There are people that like to teach, and there are people that like to pound their chest and put ya down.  Try to find someone local who is a teacher.  They're out there."Any day above ground is a good day"http://www.farmersamm.com/
Reply:Nice first project. When I read the intro I didn't expect such a well executed project and the results are great. Great machine work and the design is clean. I like ambitious projects that force one to obtain a whole host of new skills. Experience gained from projects like this are priceless. Hopefully these burners will last as long as the rest of the bbq!
Reply:Looks good and well designed for a first for sure...wish I had lifetime burners in mine LOL. The BBQ may fall apart around them they look pretty stout...and I don't thing anyone wants to look at your welds while it's on Lincoln 225 Tombstone,Miller Big 20,Hobart 180,150' Argon,A/D hobart hood 22 Ton Log splitter,79 F350 dump eats 4.75 TONS and still turns cutters,grinders,And a  Hypertherm POWERMAX 30
Reply:Cool machining and I'm right there with ya on the tig skills....all we need is a little time behind the pedal. nice projectJerodHypertherm 30Miller Syncrowave 200Millermatic 140and a propane torch and hanger if all else fails
Reply:Marcel_r, looks like darn good work for your first go around; what kind of amperage were you using?Rick V
Reply:FANTASTIC Job !I like the way you laid it all out and made sense of the photos while INCLUDINIG your mistakes...   Easy to read and no guesswork for the reader/viewer.  Well done...Cheers,/Joe..Miller Diversion 165120 amp Buzz BoxVictor Oxy/Ace Oxy/LPGSmith "Little" Oxy/LPGHypertherm Powermax 30Lot's of Misc. tools n' crap....
Reply:Rick,For most of the work I was using 125A..  using 3/32 tungsten and 316L filler on most of the welds (except for the Mixing chamber to feeder tube which was all 304).Stainless doesn't draw the heat away like Aluminum does and I was going for about .1" penetration in most cases...I wasn't too worried about structural integrity on this one... I figure if it could hold the gas I was good :-). Originally Posted by Rick VMarcel_r, looks like darn good work for your first go around; what kind of amperage were you using?Rick V
Reply:Nice job, sink or swim, nothing like starting a decent project to make sure you get it right. Looks like it works well, and as someone  said before " who cares about your welds so long as it cooks the food"  and if it holds together you have accomplished both. sizzle sizzle, Miller Auto Invision 456 + S-62 wire feederC6240B1 Gap bed lathe16 ft3 air compressor16 speed pedestal drillHafco BS-912 Bandsaw
Reply:I would say an extremely nice turnout, good job Age:17Machine: Lincoln AC 225v Arc WelderMotive: TO learn everything i can about weldin
Reply:natural gas or propane?
Reply:Natural Gas Originally Posted by oxy moronnatural gas or propane?
Reply:AWesome!!
Reply:i would love more info on the venturi design, please.
Reply:Sweet! Nice job! Is there a chart somewhere that you can look up what metal you are using and it will tell you what filler rod to use?- mototig2010 Everlast Power Ultra 205-----50A Plasma / 200A Tig / 160A StickLincoln Arc 225ACNorthern MIG 130
Reply:I used two different SS variants.. I used 316L Schedule 40 Pipe for the burner tubes... I figured that this stuff is targeted for corrosive environments and I guessed it would handle the "burn" better.  I used 316L filler 1/16" rod for all the welding on the burner tubes and where the tubes joined the cross piece.I used 304L for the cross piece, feeder tube and for the Venturi / air valves (mostly cause I hate machining 316.. nasty stuff). I used 308L, 1/16 filler for welding those parts.Some misc bits (legs, "flavor bars" supports, etc) 304L stainless welded to the burner tubes with 316L filler where necessary.--marcel Originally Posted by mototigSweet! Nice job! Is there a chart somewhere that you can look up what metal you are using and it will tell you what filler rod to use?
Reply:That is a fine job!Would you be averse to the nickname William Schaucker?Oh,  I am sorry......I'll bring some ribs and sauce. Last edited by tanglediver; 05-11-2010 at 11:34 PM.City of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:But... Attached ImagesCity of L.A. Structural; Manual & Semi-Automatic;"Surely there is a mine for silver, and a place where gold is refined. Iron is taken from the earth, and copper is smelted from ore."Job 28:1,2Lincoln, Miller, Victor & ISV BibleDanny
Reply:tanglediver, Oh, that one shuts down automatically once both the inside and outsides are lit :-)Note that it has a mirror "match" on the other burner :-) Originally Posted by tanglediverBut...