New Bridge Project

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I've built several of these before. I thought I'd share some pics of the process just in case you ever need a bridge.Here is what we're after.Last edited by TPnTX; 04-05-2006 at 08:19 PM.
Reply:Okay so the 1st thing to do is to bend the rails. I need a 127" radius using 1" 16 gauge square tube. So I make a jig at 70" radius. When you bend the 1" it springs back to about 127" radiusLast edited by TPnTX; 04-05-2006 at 08:20 PM.
Reply:heres another shot
Reply:what I end up with is 5 almost identicle bends. One of those is twisted you have to be careful. I'll use it for sub rail.Last edited by TPnTX; 04-05-2006 at 08:21 PM.
Reply:I've got a collection of different jigs
Reply:after cutting the radius 1" pieces to 9' span, I weld on the legs using 1 1/2 square tube.
Reply:And then you join the with a 1 1/2 brace.
Reply:tomorrow I'll weld on the pickets, the sub floor piece and take it to the powdercoat place. All thats left then is to cut the board and attach them. Oh and collect some cold hard cash.
Reply:Cool! Where does the sub floor pce go? Centerline? How do you connect the wood? Tabs? To the sub pc? Close up pics please!! Details, always the details. Nice ideas.
Reply:I'll weld a 1" strip to each bottom rail on the inside flush with the bottom. Then bolt each board using a 1/4x 1 1/2 carrage bolt. I have to drill each hole in the strip. I could get the stip punched but I like drill the hole precisely where I want them. The sub rail will run center of the braces and I'll bolt each board to it using a 2" carrage bolt.
Reply:Pretty nice and simple too. Just enough difficulty factor with the arched pieces to keep the average weekend gardner from doing his own. Repeatable if a guy saves the jigs like you did. I see you leave a small leg, maybe 8 inches or so on the bottom??
Reply:Yep. You build one of these and you're an artist. You build a fence and be off by 1/2 inch and you're a smuck.The leg helps a lot. You just dig a small hole and little concrete and it ain't going no where. Here is the first one I ever did. I'd been welding for a while using my stick. A friend loaned me his MIG and I made the bridge. By the time I drove to Shreveport from Dallas is was falling a part. I basically caulked it together. So I limped home and welded the **** out of it.I'm much better now
Reply:I built myself a little bridge a while back. Of course it was a "wee bit" bigger than yours, but I cheated and used power rolls.The main bridge structure is Aluminum- 2x2x1/4" square tubing, with 1 1/2" pipe for the rails.The fish is 3/8" stainless.Its 40 feet long, 4 foot wide planks of full 2" doug fir, bolted down with 1/2" carriage bolts, and about 12 feet tall. Attached Images
Reply:Here it is in the shop- it kinda filled up the whole shop. Attached Images
Reply:TPnTX,thanks for sharing the bridge building method, very nice!
Reply:There will always be someone to "ONE-UP" ya!  And I like it when they do. Not to be a jerk...but just to get the chance to see some of the really cool things that this forum brings together. Oh, and I WAS going to say that there was something FISHY about that bridge.....
Reply:No one "one upped" me. I bought all materials for this bridge from King Metals and fabricated it using an HF 120v wire welder. I think it still there connecting the US to Hawiaii.
Reply:Not really...Here's the finished bridge.
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Reply:I just didnt have a big enough trailer for my bridge- so we had to kinda fake it. If you take the corner too fast, you end up with a nissan pickup with a bed that is wider at the back than at the front- dont ask me how I know this. Attached Images
Reply:Here one that I built for a friend so he could run a Skidsteer with a full bucket of sand, to put in a putting green and sandtrap. Then use his golf cart to get to the green side. He had me put a T-Post in the middle of the bridge because he wanted to be safe and not have the bridge cave-in, I told him he didn't need it, but the customer is always right, beside he was paying by the hr. He poured a concrete pad under it to be safe. After the concrete settled and sank about 2", the T-post never touched the pad, even with a fully loaded Skidsteer. I told him he wouldn't need it.LOL Attached ImagesLast edited by UP BRETT; 04-16-2006 at 04:33 PM.Brett B & B Fabrication and Welding Inc.Spalding, MI.
Reply:This Bridge was installed at a home located on Lake Lewisville(aka Lake Dallas) This is arguably the nicest lake front property in DFW known as Lake Highlands. Only in the last 10 years or so have you been able to build a home on the shores of Lake Lewisville. This particular location is THE finest cove on the lake and homes built on the cliffs are magnificent. I'm sure with a staggering price tag.The are five giant houses that overlook a small park area at the bottom of the cliffs. My friend Steve Bowen landscaped this area which included a bridge. This is about an hour away for me and I finally got a chance yesterday to drive out to shoot some pictures. It's so beautiful. I took probably 20 shots from every angle. When I got home I pluged in the camera to my wifes PC where she was working  so she could see the images. She accidently deleted all but one image off the camera and they don't go to the trash can. You delete them and they are gone. So here is the one image that I have. It doesn't do justice to the setting and the bridge is the focal point of the entire scene.Last edited by TPnTX; 04-20-2006 at 10:47 AM.
Reply:Originally Posted by TPnTXThis Bridge was installed at a home located on Lake Lewisville(aka Lake Dallas) This is arguably the nicest lake front property in DFW known as Lake Highlands. Only in the last 10 years or so have you been able to build a home on the shores of Lake Lewisville. This particular location is THE finest cove on the lake and homes built on the cliffs are magnificent. I'm sure with a staggering price tag.The are five giant houses that overlook a small park area at the bottom of the cliffs. My friend Steve Bowen landscaped this area which included a bridge. This is about an hour away for me and I finally got a chance yesterday to drive out to shoot some pictures. It's so beautiful. I took probably 20 shots from every angle. When I got home I pluged in the camera to my wifes PC where she was working  so she could see the images. She accidently deleted all but one image off the camera and they don't go to the trash can. You delete them and they are gone. So here is the one image that I have. It doesn't do justice to the setting and the bridge is the focal point of the entire scene.Not being able to edit could clean a dirty carpet. Tom's bridge is kewel.  It's also quite strong.If I get this job it will be a ton of fun.  I've suggested a combination of stone and steel that I think will work with this property.life is good
Reply:I think that it is truly wonderfull that you all get opportunities to cross paths (pun  ) like this.
Reply:Very nice stuff fellas !  I enjoy seeing what everyone is building. Gives me ideas, but no time. Hahhaaa!John -  fabricator extraordinaire, car nut!-  bleeding Miller blue! http://www.weldfabzone.com
Reply:Man wadda-ya know! I think thats great. There is a correction to the post I noticed right after I started it. Its not Lake Highlands it's Highland Village off Lake Lewisville. I didn't think anyone would catch or that it really mattered. Just goes to show....Thanks for the complements Harv, I'm glad someone got to see it.I don't think Steve will get his feelings or his wallet hurt Last edited by TPnTX; 05-25-2006 at 01:02 PM.
Reply:Harv do you know who the owner of the house is? I haven't verifiied this but I think he's on up there for Sam's Club. They did a photo shoot out there a couple of weeks ago. I'm not sure but the shoot was for some promo at Sams' club and supposedly the bridge was photographed heavily. There a chance it may be seen at Sam's
Reply:Originally Posted by TPnTXHarv do you know who the owner of the house is? I haven't verifiied this but I think he's on up there for Sam's Club. They did a photo shoot out there a couple of weeks ago. I'm not sure but the shoot was for some promo at Sams' club and supposedly the bridge was photographed heavily. There a chance it may be seen at Sam's
Reply:TPnTX, that's an excellent design and beautifull craftsmenship.  I had to click the monitor off last night when i had your first pic up on the screen.  If my wife had seen it, i'd be making steel bridges for a living.  she and all of her friends would be buggin me to make one.  Good gift idea.  nice job.  you have any more pics of projects you've done?  always nice to see well built products.
Reply:Hi, Baby...Daddy... (you know I feel uncomfortable calling a guy baby) Hehe I just kidding you...Well no I'm not dang it. I'll just call you Babe. Anyway thanks, Here  is a slide show of some jobs in the last year.There is one pic of this extremely beautiful entry gate...I didn't do that. We did the Landscape. It's funny back then I sub'd out for a guy and did all that work and now he works for me.Last edited by TPnTX; 05-27-2006 at 08:33 AM.
Reply:Originally Posted by TPnTXHi, Baby...Daddy... (you know I feel uncomfortable calling a guy baby) Hehe I just kidding you...Well no I'm not dang it. I'll just call you Babe.
Reply:Originally Posted by RiesI just didnt have a big enough trailer for my bridge- so we had to kinda fake it. If you take the corner too fast, you end up with a nissan pickup with a bed that is wider at the back than at the front- dont ask me how I know this.
Reply:["baby's daddy" was on my mind when i signed up]HA! well I guess we should all be greatful what was one your mind at the time...could of been worse, right  Momma's Daddy, Bad Daddy...  Hey thanks for kind words, I had some help with scrolls. A local blacksmith made them. Once they where all straightend out and made uniform they lined up pretty easily. I was a little nervous making that thing though. I was worried it would not come out nice and I had a lot riding on it. But the Damsel was very very pleased and so was I.
Reply:Well Tom it looks like I got the job.  I'll be starting it in two weeks.  It should be a ton of fun.life is good
Reply:well good, I'll have to come out and see you. I talked to my friend and he wasn't bidding on that one but knows the company that was taking the bids. I'm glad you got it. I'm a little tired right now, I'm getting my butt kicked by a fence. I was thinking of your fence stretcher today. I foolishly bought a stretcher from TSC. The top strands came loose and I bent the stretcher in half with my tractor. I must of stood and stared at it for 15 mins in the hot sun.There is a farm supply store around the corner on Hwy 276 a lady named Sue runs it and she knows her stuff. She had a stretcher that uses wedges and it's pretty sturdy. I won't be folding it in half at least. I'll try again tomorrow.Do you use the crimps to splice fence? I'm having trouble with those too. The kind I have I got from TSC. (I'm beginning to hate that store) They are shaped like this.......  (00) I'm using Red Brand 4' Horse fence with 2x4" square. The crimps did not hold. So I ended up bending and tying themI've gained a huge amount of respect for this fence. It's the 1st time in a long time that I've come across something I can't make right.I think the $140.00 stretcher I bought today will work. I'm not too concerned about the crimps not holding. I can tie it off at the splice. The one thing that I've not gotten to yet and I'm not sure how to handle is pulling past my post to stretch tight. If I do that can I just cut one strand at a time and tie it? Starting with the top and bottom?Last edited by TPnTX; 06-02-2006 at 09:57 PM.
Reply:Originally Posted by TPnTXwell good, I'll have to come out and see you. I talked to my friend and he wasn't bidding on that one but knows the company that was taking the bids. I'm glad you got it. I'm a little tired right now, I'm getting my butt kicked by a fence. I was thinking of your fence stretcher today. I foolishly bought a stretcher from TSC. The top strands came loose and I bent the stretcher in half with my tractor. I must of stood and stared at it for 15 mins in the hot sun.There is a farm supply store around the corner on Hwy 276 a lady named Sue runs it and she knows her stuff. She had a stretcher that uses wedges and it's pretty sturdy. I won't be folding it in half at least. I'll try again tomorrow.Do you use the crimps to splice fence? I'm having trouble with those too. The kind I have I got from TSC. (I'm beginning to hate that store) They are shaped like this.......  (00) I'm using Red Brand 4' Horse fence with 2x4" square. The crimps did not hold. So I ended up bending and tying themI've gained a huge amount of respect for this fence. It's the 1st time in a long time that I've come across something I can't make right.I think the $140.00 stretcher I bought today will work. I'm not too concerned about the crimps not holding. I can tie it off at the splice. The one thing that I've not gotten to yet and I'm not sure how to handle is pulling past my post to stretch tight. If I do that can I just cut one strand at a time and tie it? Starting with the top and bottom?
Reply:thanks I will.
Reply:We started the job Monday.  The first thing we had to do was set posts.Hey, I'm a fenceman.  The first thing we do is set posts. Attached Imageslife is good
Reply:Then yesterday we started placing the rails in place.Remember, I'm a fenceman, I look at things like they're a fence. Attached Imageslife is good
Reply:One of the things that make this job special, besides Tom Penny being on site, is the change in grade.We park the truck in the neighbor's driveway.Then everything has to be hauled down along the side of the house.Keep in mind the Maximizer concrete came in eighty pound bags, the posts were three and a half inch schedule forty pipe, and the rails are fabbed from four times four times three eighths angle at nine dot nine lbs per foot. I cut them into ten foot sections so we could haul them down the bank. Attached Imageslife is good
Reply:That's a nice bridge Tom, well everyone elses projects look good too.DewayneDixieland WeldingMM350PLincoln 100Some torchesOther misc. tools
Reply:Thanks fuzzYeah I got stop by and see Harv and John yesterday. I gotta tell ya, I was tired from just standing on that hill talking for a few minutes. Working all day on that grade has got to be tough. Since you won't hear Harv complain I thought I'd complain for him.
Reply:Tom came by again yesterday.  He had his son with him who appeared a little bored until this really neat lizard made an appearance.Tom's got a job in the neighborhood and we like to visit. I've basically got the support system for the walkway cut in.  Today if the weather cooperates I'll have it welded up. Attached Imageslife is good
Reply:When I got down to the big turn I realized I needed to either make a little landing for the turn or drag down the digging equipment and concrete plus a new post.I decided to improvise a landing. One of the most common questions I see on the welding forums is how to cope or notch pipe.  This is three and a half inch schedule forty pipe and I wanted to lay out a brace.I did this cut with a portaband saw and then touched it up with an angle grinder.  Most of the time the cut can be done close enough with just a saw cut. Attached Imageslife is good
Reply:This is not one of those calculated braces that engineers do. It's one of those weldor in field wants to change the pressure points on a joint things. Attached Imageslife is good
Reply:One of the handiest things a weldor can have on a jobsite when it's hot and dry is a common pump up sprayer set on mist.  It works for the weldor's temperature control.  And it'll put down a small fire in a heart beat. Attached Imageslife is good
Reply:I guess since the job is complete I can update it.We did have one incident with a city inspector.  I noticed him on top while I was welding up the legs for the handrail on the walkway.  About thirty minutes later he shows up with the fire marshall.  After the fire marshall checked me out, sprayer, fire extinguishers, charged water hose, etc, he then proceeded to dress down the inspector and give him the printed material he had for me. Evidently the inspector saw me welding and decided he would make his day by ruining mine.  I suspect he called the fire marshall hoping to get me in trouble.  Too bad the fire marshall found me doing things by the book and appreciated the work.This is a picture I took of Tom's bridge this morning. Attached Imageslife is good