Rear Cargo Rack project (for Jeep Wranger) - using Longevity MigWeld 140

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My scrap steel pile, at home, has been getting a bit out of control thanks to the overly generous help of neighbors and co-workers who have been remembering to save me scrap steel whenever they come upon it (how nice is that?!). I finally had enough donated steel to continue building the rear cargo rack for my big white Jeep. I am planning to mount the rack just above my rear spare tire (a rear-mounted rack). Most of the scrap 11-gauge (.120” thick) mild steel was bent out of shape for whatever was the original intent of the steel, so first things first, I had to straighten out the bent pieces before I could start my own fabrication of the steel and bend them to my particular specifications. Straightening out those long steel strips took over an hour of work, lots of hammering. Yikes!  For the straightening of the steel strips, I decided to pull out “Excalibur” my red 50-ounce Estwing ball peen hammer (along with my Harbor Freight orange 3-lb dead blow hammer).  You’ve gotta love how particular hammers make for the perfect tools for steel-straightening jobs where you want to apply controlled pounding force within a smaller, specific area of steel (hence the rounded end of a ball peen), but you do not necessarily want to mar the finish of the steel (hence a plastic dead blow).  Anyway, after I straightened out those steel strips, next I could finally get back to the real work with the support braces, which I had started more than one month ago.  By the way, my sketch/plan calls for the cargo rack to measure (L) 36” x (W) 18” x (H) 6”, just big enough to hold a 36- or 40-quart cooler and maybe a sleeping bag. Using a vise and a dead blow hammer, I had to manually bend the support braces.  There's even more support steel to come too--I’ll probably add two more additional support braces and at least a couple 1-inch angle iron pieces.  As for the welding machine, for starting this project I used my beloved Longevity MigWeld 140 for this phase.  I equipped this mig welder with HTP's .023” ER70S-6 mig wire (until Longevity comes out with its own solid mig wire!).  I also used a C25 gas mix (75% Argon/25% CO2) at a shielding gas flow rate of 22 CFH.  Most of my time was spent completing the fabrication of the three support braces for today. It was a big pain in the arse to bend/cut/grind the support braces to get the bend angles and the overall length & height dimensions to match to my satisfaction.  I wondered if I would have any time at all today to do some welding.  Anyway, I knew that my 55 cubic foot cylinder was already low on gas, but I did have just enough C25 gas today to weld 2 (of 4) support braces to the lower portion of the rack.  More pictures to come.  Stay tuned.  - Cheers!

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Last edited by Agape Guy; 01-20-2014 at 01:36 AM.Reason: typosAgape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:More photos of the project and the target vehicle (in the Jeep photo where the rack will be mounted above the rear spare tire, you can ignore my friend's kids playing in my car).

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Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:STILL trying to perfect the stack of dimes technique!  Some day.Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:This weld I cut short on its left side.  STILL trying to perfect the stack of dimes technique!  Some day.

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Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:Here's the more-completed base, which will be the foundational basis for the remaining fabrication of the rack. I have to re do some of the welds, because I tried to rush them when I discovered I was running low on C25.

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Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:No comment on your rack because I can't figure out exactly what you're doing. But I did notice that your MIG welder face plate looks kinda wonky. Is the plastic too thin ?
Reply:

Originally Posted by Agape Guy

More photos of the project and the target vehicle (in the Jeep photo where the rack will be mounted above the rear spare tire, you can ignore my friend's kids playing in my car).
Reply:BTW, the rack that I'm still fabbing will be squared up with right angles using a lot of flat stock sheet strips  all around. And the "mounting" plan is to attach the rack only to the roll-cage for its sole support, much like the Kawasaki rack here is mounted, which is pictured here merely for illustration purposes only. I really like the design of this simple mounting concept.  That's the plan anyway.

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Last edited by Agape Guy; 02-11-2014 at 10:11 PM.Reason: TyposAgape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:For the sticker on the MIGWELD 140, we have fixed the issue and decided to not do stickers anymore and print on a plastic panel - the last shipment contained the new display. If it bothers you, we can send out another sticker or replace your machine for a permanent fix. We are here for you!Cheers

Phone: 877-566-4462 x 201Email: [email protected]: www.longevity-inc.comEmail for any questions about LONGEVITY!
Reply:That's what I love so far about Longevity. Any issues and they always offer a solution!!MillerMatic 140Longevity 42i
Reply:

Originally Posted by LONGEVITY-Simon

For the sticker on the MIGWELD 140, we have fixed the issue and decided to not do stickers anymore and print on a plastic panel - the last shipment contained the new display. If it bothers you, we can send out another sticker or replace your machine for a permanent fix. We are here for you!
Reply:You're definately a stand up guy Agape, and that was a very generous offer Simon.  It's pretty impressive to see a company back their product like that.

Originally Posted by Agape Guy

Hi Simon.  Thanks for the offer.  I'm pretty happy right now.  One day, I might take you up on your offer to send me a new faceplate sticker.  It doesn't bother me yet though.  I'll yet you know; maybe after another summer.   (And I appreciate the alternate offer too for a new replacement machine--but in my book, it's just too much to ask from any manufacturer for the issue at hand.)  - Cheers!
Reply:We finally had another sunny Saturday in Northern California, so I could get back to doing some more work on this rack.

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Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:That looks like a good test for the MIGWELD 140. Thanks for sharing. We just returned from Toronto, and glad to have the Northern Cali weather again!Cheers

Phone: 877-566-4462 x 201Email: [email protected]: www.longevity-inc.comEmail for any questions about LONGEVITY!
Reply:

Originally Posted by LONGEVITY-Simon

That looks like a good test for the MIGWELD 140. Thanks for sharing. We just returned from Toronto, and glad to have the Northern Cali weather again!
Reply:Happy soon-to-be New Year, everyone!  I went to "heaven" today since there was finally a sunny day in Northern California to do some welding, I am not working at the moment, and I also just wanted to visit the LWS and say hi to the owner, who I had not seen in awhile--he's a good guy and a terrific welding resource.  He did not mind me bringing along my MigWeld 140, so I could weld in his parking lot and also just BS with a couple of professional welder buddies (they are also on vacation for a few days) who hung out for a few hours and had fun teasing me about my welding skills.  Anyway, the rack project is coming together.  This project is a really good test for this 110V machine and for experimenting with different welding processes (gas, flux core).  While I was welding using flux-core wire, I ran out of wire so I tried a never-before-used WeldCote brand in E71T-GS in .030", because that was the available option at the store.  The WeldCote brand works well, at least with a 110V welder---my .02 cents.

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Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:Thanks very much for sharing and updating the thread! Glad you guys got some laughs off and more people were able to check out the performance on the MIGWELD 140LONGEVITYPhone: 877-566-4462
Reply:BTW, there is a side project to my cargo rack project---here's the "logo" concept for the rear long side of the rack that will be facing the rear (I'm obviously NOT an artist!).  Anyway, now that I just recently purchased a plasma cutter, I'll be making the actual logo on sheet metal and make it a lighter blue color to match the safari door colors that I fabbed for my Jeep; eventually, I'll be welding the logo piece on the back of the rack.  Something like that.  I'm working with an artist buddy, who is really into brush art.  He's the one that cleaned up the concept for the logo and made it ready for me.  Now, I just have to buy the wood, cut the stencil from the wood, then finally lay the stencil over the steel workpiece and cut out the logo.  Not sure what sheet metal thickness I should make the logo.

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Last edited by Agape Guy; 04-30-2015 at 03:01 PM.Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools
Reply:

Originally Posted by Agape Guy

Happy soon-to-be New Year, everyone!  I went to "heaven" today since there was finally a sunny day in Northern California to do some welding, I am not working at the moment, and I also just wanted to visit the LWS and say hi to the owner, who I had not seen in awhile--he's a good guy and a terrific welding resource.  He did not mind me bringing along my MigWeld 140, so I could weld in his parking lot and also just BS with a couple of professional welder buddies (they are also on vacation for a few days) who hung out for a few hours and had fun teasing me about my welding skills.  Anyway, the rack project is coming together.  This project is a really good test for this 110V machine and for experimenting with different welding processes (gas, flux core).  While I was welding using flux-core wire, I ran out of wire so I tried a never-before-used WeldCote brand in E71T-GS in .030", because that was the available option at the store.  The WeldCote brand works well, at least with a 110V welder---my .02 cents.
Reply:

Originally Posted by longevity-inc.com

Thanks very much for sharing and updating the thread! Glad you guys got some laughs off and more people were able to check out the performance on the MIGWELD 140
Reply:I like the owner of welders heaven. Old school guy, who will offer you a beer.
Reply:

Originally Posted by SolidCore

I like the owner of welders heaven. Old school guy, who will offer you a beer.
Reply:The 1/2"-thick wood stencil is done, thanks to an air-brush artist buddy.  Now it's plasma cutter time---I'll lay this wood stencil on top of a sheet of mild steel (~10 gauge) and cut out the 9" x 15" logo.  But first, I'll do a search here on weldingweb (and youtube) to look for tips/guidelines for cutting out designs with a stencil using a plasma cutter.  Please send me any links you think will help, since this is my first project with my plasma cutter.

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Last edited by Agape Guy; 05-10-2015 at 06:19 PM.Agape GuyEverlast Power I-MIG 200 (dual voltage)Everlast PowerArc 200 stickHarbor Freight Titanium 125 Easy FluxHypertherm Powermax 30Way too many power tools