This Weeks Fun

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I got these in monday.  I knew they were coming, and this is what I bought the positioner for.  Last year I did 23 for the same customer.  I didn't have pulsed spray or the positioner.  I migged a few, but they had leaks, so I tigged the rest.  This year there are 45 instead of 23.  I have better equipment and get the SAME price each.  They come assembled.  I took one apart to show what I am dealing with.  These are heat exchangers of some kind.  They will be pressure tested at about 45 psi.  NO leaks are allowed.  If one leaks, I get to fix it for free.Here is the plate.  2 of these make up the box.ThicknessSide plates drilled and tapped.  There are fins inside and 4 tubes to keep things in place. Thin to thick.  Sorry for the blurr.  Sometimes that is how it looks to me .  Plate is 3/8"Here it is assembled.  Note where the bolts are.  I have to move them because if I weld it as is, it warps.Last edited by David R; 03-26-2008 at 07:10 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I move the bolts to the center.   My customer said next time he will put them in the center for me.Next I wire wheel any where I am going to weld.  There is some "stuff" on the edges of all the plates.  Its gotta go!  Note the gap in the plates.  Its gotta go too.2 clamps to get rid of the gap and one quick tack with the tig to hold in place.  Same for the opposite corner.This is my setup for this job.  Positoner pedal on left, tig pedal on right. Wire cutters for mig, LOTS of tungsten cause I tend to dip too often.  Workbench is too tall, so I used the metal sawhorse and a stool.This little corner is the hardest part and where  I would expect a leak.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:From this seat I'm reading .133 thick..I'm gonna send you some dial calipers.....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 tig all 8 little corners.  Then I pulsed spray  all the seams.  When done, the original tig welds won't be seen.  I could do it without them, but insurance is cheap.  NO LEAKS.This is the first pass ONE pass.  I use the positioner to make the corners.  It saves me trying to manipulate the gun.This is the long pass.  I tried forehand, back hand, 98/2 and 92/8.  I settled on 92/8 and straight in (gun square to fillet)I wrap around the corner with the positoner.  You can see I "ride  the cup".  I just drag the gas cone along the plate pointing the arc directly into the root.These couplings go in the holes.  On the left is a tool with a magnet on top.  Just place and tack.Last edited by David R; 03-26-2008 at 07:41 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Originally Posted by zapsterFrom this seat I'm reading .133 thick..I'm gonna send you some dial calipers.....zap!
Reply:Tack in place.Weld with positioner After they are welded, I start the next one while the last one cools.  I then wire wheel the whole thing and look for anything that could be a leak and fix it with the tig.After they go back to be "stuffed" (the rest of the tubes put in and rolled) these blocks will be welded on.They need to be welded inside here.I hacked up my positioner plate so I could do this job.  A new plate is twenty bucks.  I'll keep this one as is for next time I get this job.Note the grounds, one from each machine.Last edited by David R; 03-26-2008 at 07:27 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Here are 10 done except the couplings.  The tool need a little mod so I did what I could.   These need to be done and shipped by wed.The one on the left is bent plate, the one on the right is welded.  PULSED SPRAY ALL THE WAY!NO stinkin dimes.Here are the rest just calling my nameReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Settings:It sez .030 steel wire, 92/8, 364 ipm.A days worth of tungsten.  Thanks for watchingMan I love this job!DavidLast edited by David R; 03-26-2008 at 07:30 PM.Real world weldin.  When I grow up I want to be a tig weldor.
Reply:You 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:Lookin' good David.
Reply:love this kind of stuff6G zirconium 702 GTAW 2" xxheavy6G P.E.D. carbon steel GTAW 2" xxheavy3G titanium Gr. 2 - Gr. 7 GTAW up to 3/4" 3G 316L stainless GTAW up to 1" 3G carbon steel GTAW up to 1" 3G Hastalloy GTAW up to 3/4"1G tantalum GTAW up to .060"
Reply:That's cool stuff - Watching projects like this really helpful!Thanks for sharing!-Chet---------------------------------Miller Dynasty 200DXMiller Spectrum 375 Extreme
Reply:Originally Posted by zapsterFrom this seat I'm reading .133 thick..I'm gonna send you some dial calipers.....zap!
Reply:nice work Dave .......are u gonna build a roll cage for the little lincoln ?63' Lincoln SA200 2008 miller trailblazer 302fibre-metal pipelinermiller camo BWEand all the guns and ammo a growin boy needs
Reply:Nice work as usual. I still get a kick at how much tungsten you have.Miller Syncrowave 200Hobart Handler 140Thermal Dynamics Cutmaster 38E-Z Tube BenderPlasma Cam DHC2
Reply:Way to knock it out Dave! I feel ya on the tungsten, sometimes I go for days, and other days I am dippin every 5 minutes!Yup
Reply:Originally Posted by zapsterFrom this seat I'm reading .133 thick..I'm gonna send you some dial calipers.....zap!
Reply:Oops, wrong button. I was going to say... nice write up David, keeping busy is the best way to run a business! Last edited by tanglediver; 03-26-2008 at 10:51 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:You know you could sharped the other end of the tungsten and effectively get twice as many.Have we all gone mad?
Reply:Originally Posted by sn0border88You know you could sharped the other end of the tungsten and effectively get twice as many.
Reply:Originally Posted by sn0border88You know you could sharped the other end of the tungsten and effectively get twice as many.
Reply:Originally Posted by usmcgremlinnice work Dave .......are u gonna build a roll cage for the little lincoln ?
Reply:David why is it that the beads look so grainy ? I don't get it as other PSM work I have seen is smooth and almost looks like it has been dressed out with a flap disk. I understand it is production type work with this job....why not simply spray transfer why pulse...... I know you don't want it to warp and flex etc.
Reply:Nice job Dave. I wish I could land a job like that at times. I think I may look into a positioner now. After seeing Zaps and now yours, it looks like a great tool to have.Miller DVI2Lincoln Precision Tig 225Thermodynamics Cutmaster 38Everything else needed.
Reply:Dave i am very familiar with your machine. It is one of my favorites. i talked with my instructor about getting those machines for the school. i set up 20 of them.63' Lincoln SA200 2008 miller trailblazer 302fibre-metal pipelinermiller camo BWEand all the guns and ammo a growin boy needsDavid, if practice makes perfect you should be pretty close by the time you get done with that stack in your picture. Good looking job. I won't quibble about the thickness of the metal, after all tolerances aren't held that closely on plate especially if it is of foreign manufacture. All ways interesting to see some one's procedure on welding projects.
Reply:Couple of comments, first, if you hit the corner of the tube plate with a grinder, you wouldn't have to "pre-stress" the plate (see third pic., post 2), tha 90 degree cut is fouling on the radius of the bend.second, i agree with 84z, that's spray? pulsed or not, it's terrible, (filthy and wavy).
Reply:Filthy, wavey? Am I missing something here? Looks fine to me...Airco 300 squarewaveMig welding center...Powcon sm300/LN 25Powcon sm200/PD lHypertherm PM 1100Miller AEAD 200LE W/LN25 FCand now another sm200 pd l combo.
Reply:Originally Posted by ChamferTrodeCouple of comments, first, if you hit the corner of the tube plate with a grinder, you wouldn't have to "pre-stress" the plate (see third pic., post 2), tha 90 degree cut is fouling on the radius of the bend.second, i agree with 84z, that's spray? pulsed or not, it's terrible, (filthy and wavy).
Reply:Originally Posted by 84zmikeDavid why is it that the beads look so grainy ? I don't get it as other PSM work I have seen is smooth and almost looks like it has been dressed out with a flap disk. I understand it is production type work with this job....why not simply spray transfer why pulse...... I know you don't want it to warp and flex etc.
Reply:Originally Posted by ChamferTrodeCouple of comments, first, if you hit the corner of the tube plate with a grinder, you wouldn't have to "pre-stress" the plate (see third pic., post 2), tha 90 degree cut is fouling on the radius of the bend.second, i agree with 84z, that's spray? pulsed or not, it's terrible, (filthy and wavy).
Reply:Originally Posted by usmcgremlinDave i am very familiar with your machine. It is one of my favorites. i talked with my instructor about getting those machines for the school. i set up 20 of them.
Reply:can you "just" MIG them...no pulse or spray....that would help with the smaller bead the customer is requesting
Reply:these are half of them63' Lincoln SA200 2008 miller trailblazer 302fibre-metal pipelinermiller camo BWEand all the guns and ammo a growin boy needs
Reply:Originally Posted by usmcgremlinthese are half of them
Reply:Originally Posted by 84zmikecan you "just" MIG them...no pulse or spray....that would help with the smaller bead the customer is requesting
Reply:You guys were right!I was changing settings and trying more things today and HOLY COW it looks better.  Bottom line, the arc was too long.  I have more control and it looks MUCH better.  Can't find my camera, but maybe pics tomorrow.Thanks a bunch David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Of course we're right, we wouldn't bust your balls for no reason DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:No updated pics.? what did you change.....
Reply:I got pics today, post em tonight.  What did I change?  Wave control all the way up (less background current and higher frequency) and make the arc shorter (turned the machine down).David <~~  Big cheesy smileReal world weldin.  When I grow up I want to be a tig weldor.
Reply:Here are the latest.  Today (yeah, sunday) I ran out of Linconl L-56 and put in a new roll of harris .030 ER70S-6.  It was not near as shiny on the outside.  It welded much different.   I even had to readjust the welder.   I took a few pics.11 left!David Real world weldin.  When I grow up I want to be a tig weldor.
Reply:I must have had the heat perfect because I almost burned through on this one.I had JUST enough tungsten.  Prolly about 40 pieces there.  One left.Mission accomplished!Thanks for watchingDavid Real world weldin.  When I grow up I want to be a tig weldor.
Reply:Looks like a great job!I know your enjoying the pulse spray.Better than last year eeh?      weld it like you own it
Reply:Originally Posted by David RThe clamps get rid of the gap. Look at the pic above that one.  I am not that good of a weldor to deal with such poor fitup.  It would just burn through.  If the plate was bent a little more, the gap would be gone.  I just close it up with  clamps.  How would a grinder help?  Pic #2 post #7 heat exchanger on the right is that gap after clamping and welding.    Does it look that bad?I can't re engineer the customers work.  The tube plate is machined.  I aint touching it with a grinder.David