Welding/Fabrication thread

[joshg123]

Since alot of us are DIY'ers i thought a topic where we could post up our works, questions and how to's. I enjoy welding and fabrication in my spare time, however im certainly no pro. I self taught myself on the tig welder and am doing some turbo manifolds on the side for a little pocket money.

One thing i really struggle with is alluminium, just cant get a nice bead when joining two bits of ally together of the same grade. I can run a bead fine, but when it comes to joining two bits together, just struggle town.

What equipment are you all using? I am using a old Cigweld girl, rigged up a water cooler, 180amp 3phase ac/dc. Seems to do the trick but i dont think its a match for the inverter welders of today, the transformer in this one feels like its going to take off.

http://i6.photobucket.com/albums/y220/joshg123/IMG_0088.jpg

http://i6.photobucket.com/albums/y220/joshg123/IMG_0084.jpg

Anyone else into learning to weld?

[iluv2moan]

not quite as impressive as yours but heres my first attempt in the making... have put it on hold since i picked up blaas trust mani but wihen i finish it off, will test it back to back with the trust mani to see the difference


http://img143.imageshack.us/img143/9771/p9111720.jpg (http://img143.imageshack.us/i/p9111720.jpg/)
http://img42.imageshack.us/img42/9386/p9111721.jpg (http://img42.imageshack.us/i/p9111721.jpg/)
http://img143.imageshack.us/img143/858/p9111722.jpg (http://img143.imageshack.us/i/p9111722.jpg/)
http://img143.imageshack.us/img143/1033/p9111723.jpg (http://img143.imageshack.us/i/p9111723.jpg/)
http://img44.imageshack.us/img44/2344/p9111724.jpg (http://img44.imageshack.us/i/p9111724.jpg/)
http://img143.imageshack.us/img143/5199/p9111725.jpg (http://img143.imageshack.us/i/p9111725.jpg/)

http://img509.imageshack.us/img509/8176/p9121728.jpg (http://img509.imageshack.us/i/p9121728.jpg/)
http://img183.imageshack.us/img183/4731/p9121729.jpg (http://img183.imageshack.us/i/p9121729.jpg/)
http://img21.imageshack.us/img21/8474/p9121730.jpg (http://img21.imageshack.us/i/p9121730.jpg/)
http://img3.imageshack.us/img3/2083/p9121731.th.jpg (http://img3.imageshack.us/i/p9121731.jpg/)
http://img22.imageshack.us/img22/8866/p9121734.jpg (http://img22.imageshack.us/i/p9121734.jpg/)
http://img186.imageshack.us/img186/163/p9231739.jpg (http://img186.imageshack.us/i/p9231739.jpg/)
http://img248.imageshack.us/img248/1570/p9231740.jpg (http://img248.imageshack.us/i/p9231740.jpg/)
http://img242.imageshack.us/img242/2627/p9241740.jpg (http://img242.imageshack.us/i/p9241740.jpg/)
http://img22.imageshack.us/img22/4943/p9241739.jpg (http://img22.imageshack.us/i/p9241739.jpg/)

[duste]

Turbo manifold looks good Josh, can't wait to have it on the car.

I'm pretty keen on learning how to weld, it's just a matter of getting my hands on a welder. Was talking to a mate (very good welder) and he said honestly any welder off eBay would do fine for learning...opinions? Would highly prefer an AC/DC Tig.

[schnoods]

for a AC/DC tig with high frequency you are looking at a couple of grand straight of the bat.

Probably best to look in the quokka for a 2nd hand job, might get a name brand one for a reasonable price.

I have a small Castoline Eutectic caddy inverter welder with a tig handpiece and attachment, works very well for a scratch start set up.

[iluv2moan]

for a AC/DC tig with high frequency you are looking at a couple of grand straight of the bat.

Probably best to look in the quokka for a 2nd hand job, might get a name brand one for a reasonable price.


picked up two ( of the 15 odd) from an auction for 120 each. shame they dont have pulse though.

[Tocchi]

I weld with mig (steel and ally) alright, need some regular practice
but I haven't learnt tig yet (on to do list) .. The thing holding me back is the fact I need to buy the tig attachments for my welding machine.

[schnoods]

picked up two ( of the 15 odd) from an auction for 120 each. shame they dont have pulse though.

Any of them single phase?

I used to have a transtig180 was a good machine despite being over 20 years old.

[joshg123]

Turbo manifold looks good Josh, can't wait to have it on the car.

I'm pretty keen on learning how to weld, it's just a matter of getting my hands on a welder. Was talking to a mate (very good welder) and he said honestly any welder off eBay would do fine for learning...opinions? Would highly prefer an AC/DC Tig.


I also have a ebay inverter ac/dc welder and its no match for the cigweld 3 phase. You certainly get what you pay for in welders, my little inverter is supposedly a 200amp. I cant even get it to bead up ally. It does strange things if your welding on steel at 100amp for too long aswell, kinda like it has a voltage spaz.

Better off just getting a DC and get a miller inverter or something basic like that.

[iluv2moan]

Any of them single phase?

I used to have a transtig180 was a good machine despite being over 20 years old.

nah all industrial spec and 3 phase. the other 12 or so got snapped up for scrap copper.

dad bought a single/3 phase transtig180 at the same time which is the one i put on these forums for sale

doubt u would find many single phase welders in factorys or workshops. the ones we got were from swan tafe.

[Deke]

im a boilermaker/welder by trade. iv done a few things at home on my brothers car and mates , intercooler pipes , exhausts etc , i borrow my tig from work but i have a mig at home i bought out of the quokka brand new but for half the retail price so i got a good bargain , im also willing to give advice :)

[Scaf]

http://img525.imageshack.us/img525/4504/picture3543.jpg (http://img525.imageshack.us/i/picture3543.jpg/)\

Heres a pic of my manifolds i fabbed up.
I tacked them using a small gasless MIG, but got a mate who is a welder by trade to TIG them up for me as i wasnt really confident enough to try it myself.

[Passage GT]

keen to learn to weld, such a useful skill to have, got an old stick welder of the old mans here' but obviously not gonna cut it in automotice applications, gotta get my hands on a cheap mig i think
gq needs new floors:)

[schnoods]

One thing i really struggle with is alluminium, just cant get a nice bead when joining two bits of ally together of the same grade. I can run a bead fine, but when it comes to joining two bits together, just struggle town.




Hey man, Just read over this thread but couldnt help wonder are you using the right tungsten? The one you want would be a Zirconiated one (white tipped end) as the Thoriated (red tipped) is for DC more or less, unless you get a Lanthiated one (yellow tip) that can do both, but is a bit of a waste...

[joshg123]

Yeah mate using the white tipped for ally and changing to the red tip for steel/staino.

I think my issue is with the cleanliness of the alluminium, i bought some acetone to clean the metal and a staino brush specifically for ally.

Do you grind the tip to a point like you do with steel or leave it blunt and let it ball? I cant seem to focus the heat where i want, it just either jumps from piece to piece.

[Oversteer]

Fun and games with a tig :D

http://members.iinet.net.au/~zrinski/chevturbo1.JPG
http://members.iinet.net.au/~zrinski/chevturbo2.JPG
http://members.iinet.net.au/~zrinski/chevt1.JPG
http://members.iinet.net.au/~zrinski/chevt2.JPG
http://members.iinet.net.au/~zrinski/chevt3.JPG
http://members.iinet.net.au/~zrinski/jd1.jpg

Profit !

http://www.youtube.com/v/KUrJ_Ct80B0

[matty12]

was that turbo for a hj 60???Looks like the one i sold.

[schnoods]

Yeah mate using the white tipped for ally and changing to the red tip for steel/staino.

I think my issue is with the cleanliness of the alluminium, i bought some acetone to clean the metal and a staino brush specifically for ally.

Do you grind the tip to a point like you do with steel or leave it blunt and let it ball? I cant seem to focus the heat where i want, it just either jumps from piece to piece.

Yeah just let it ball up. Sharpen it it will ball up anyways..

Yeah a bit of pain, it is generally labelled magnetic arc blow, maybe try a tad more stick out, keep the arc shorter and hopefully it will be a bit more focused. Also try not to coil the leads while welding.

Right amps as well, been a while since i did aluminium but roughly 30 amps per mm (ie 90 amps for 3mm plate).

[Oversteer]

was that turbo for a hj 60???Looks like the one i sold.

Yeah, went on a FJ62....did you deliver it to my house ?

[matty12]

yes, yes i did.

Good to see it went to good use,was just sitting around going to waste at my house.

[S133LTR]

does machine work fall into this thread?

some turning I did this morning to make up a remote oil filter 'spin on'.

http://i92.photobucket.com/albums/l13/KINGDS13/EDU322-assign2photos001.jpg
http://i92.photobucket.com/albums/l13/KINGDS13/EDU322-assign2photos003.jpg
http://i92.photobucket.com/albums/l13/KINGDS13/EDU322-assign2photos005.jpg
http://i92.photobucket.com/albums/l13/KINGDS13/EDU322-assign2photos006.jpg

[iluv2moan]

thought u were going to double o-ring it?

[S133LTR]

thats what she said

[joshg123]

nice work!

Have you ever used one of those mill/lathe combo's KINGD? More for the hobbyist but could be usefull?

[S133LTR]

The small (under .5m) combo jobs? Like the ones in the Heir&Forbes catologue?

I havent used them but I really couldnt see them being very good especially for materials like s/s or high tensile stuff. Machines like that would be more useful for doing work with fittings/fixing where your notn trying to remove much material.

Personaly if I wanted a really basic set up that you could do a hell of alot with combined with the welders/tools you already have IMO it would be a 1.5/2m bed lathe and a small universal mill with a sliding spindel and feeding table.

[Brett_J]

Some good amateur work in here, better than alot of "tradies" I've seen. Haven't done much Tig work myself, but one day will buy one. I used to work for an engineering firm, we were contracted to The navy and Westrail, So 50% of the salt and grain containers that you will see on the train have been repaired by me,I love welding stainless, its so shiny :)
I actually pride myself on the fact Im an awesome oxy welder, its a really hard thing to master, not your high school spec either, a good strong weld is hard to do, only required for very few things these days.Good for panel beating as the weld itself is soft.
Also did a fair bit of Blacksmithing as my boss was one, he taught me a fair bit, stinky hot work, but pretty good when you make something from scratch.

[Miggy]

I'm a Boilermaker/pipe fitter by trade but I'm not very good hahaha rough enough is good enough.

[joshg123]

Finished that manifold off the other day, came out nice i thought. Just gotta do the dump pipe and weld the turbo flange and then its ready for install

http://i6.photobucket.com/albums/y220/joshg123/000_0060.jpg

[Deke]

I'm a Boilermaker/pipe fitter by trade but I'm not very good hahaha rough enough is good enough.

haha within an inch

[Brett_J]

haha within an inch

Speaking of such,You still with them dodgy fucks in Kwinny?

[schnoods]

Which mob there is so many dodgies in the kwinny strip?

[180SXTCY]

lol within an inch? the boileys at my work would be lucky to get away with +/-2mm at times....


rough kent hahaha :P

[Brett_J]

Fuck, We had tolerances of 0.5mm, if it was out it got scrapped.

[Deke]

hahaha yea i am brett but im soon to leave i only got 3 months left :) no pingpingpingping knows how to do pipe in my shop so i get huge loads of it , and have to work long hours cant wait to leave , and yea the tradys here a rough as fuck , rough as fuck

[180SXTCY]

Fuck, We had tolerances of 0.5mm, if it was out it got scrapped.

yer on something same as well, on the big trays and what not for the mining trucks doesnt effect it to much.

[Deke]

180sxtcy i was just trying to be funny with the inch thing lol ,schnoods im working at SDR

[Passage GT]

our boily's work get's x-rayed lol
but saying that even the young boily's at work are very good
much jealous haha

[fieldy]

Where the fuck do u work if its within a inch hhahaha
At work ( westrac ) all the welds get X-rayed and tested.
Ill stick to my spanner wanking :P

[duste]

Where the fuck do u work if its within a inch hhahaha


180sxtcy i was just trying to be funny with the inch thing lol

I would have thought welding would be a more difficult skill to grasp than reading.

[fieldy]

Phone net FTL....
But i might say that Manifold looks pretty smick, good job!

[Brett_J]

I would have thought welding would be a more difficult skill to grasp than reading.



lol within an inch? the boileys at my work would be lucky to get away with +/-2mm at times....


rough kent hahaha :P
...

[schnoods]

180sxtcy i was just trying to be funny with the inch thing lol ,schnoods im working at SDR

Ahh i see.

Never had the "opportunity" to work there, worked a Westerns, Doina and UGL in kwinny...

Is there an oldish bloke there named George? Old Czech bloke, looks like the monopoply man? Worked with him at Doina, was the funniest bloke only because he had a problem with the bloke working next to him lol. So much rage...

[Deke]

its funny you say that , thats my dad :) and your name is? i did my work exp at diona

[schnoods]

its funny you say that , thats my dad :) and your name is? i did my work exp at diona



Ahhh, you had the Silvia in Primer?

Im Jason (big bloke, almost your old mans size in height, fair bit more in weight though). Drove either an XR8 or a WH stato.

You Are/were doing an apprenticeship at SDR? ( I think thats why your old man made the move from Doina, plus Gerry was a pain in the arse:lol: ).


Ahh it all makes sense.:lol: He always was pissed off with the Pommy Brothers next to him, i remember him throwing a bit of angle at one of them. Good boily though, he used to punch out the steel like no tomorrow.

[Deke]

na thats the older brother im the youngest , yea he made the move becuase they took the formans (john?) son on instead of me as an apprentise , and i am now doing an apprenticeship at SDR but i finish in june , yea my old boys always pissed about something :lol:

[schnoods]

Ahh i see.

Yeah the foreman was John, he ended up getting the boot in june/july 2008, 3 weeks after i quit, the place was in shambles.

Lol i remember when Your brother rocked up and had his hair dyed red, Cam and Adam were blowing kisses and giving him wolf whistles, he didnt know whether they were fair dinkum or mucking around.:lol:

Good stuff mate, stick to your guns and it will pay dividends.

[DrNick]

I'm also keen to know what kind of a welder you guys suggest for general purpose work, would be welding steel only and a bit of stainless. Would I be able to do this with a gasless MIG? I just want to get a small welder to practice with at home so I cant really justify something that needs gas tanks to be hired etc.
I also saw the ebay 200A jobbies for under $400 and was quite interested. Is that a reasonable price to pay for something basic to learn with? I shall grab the quokka as well this morning as suggested, but I suspect that having only single phase power will limit my choices a bit too.

[Deke]

if you want to weld stainless with a mig your going to need gas anyway , so you might aswell get an argon bottle which you can use wit your solid wire mig , or you could just go stick welder and use stainless rods, i payed 600 for my 180 cig weld mig i think it is bought it from the quokka brand new the retail is over a grand i think

[joshg123]

Personally id only use a mig to tack weld anyway, so for tacking a china welder will be allright. If your wanting a good peno structual join say for a engine mount id want to use a Lincoin 180, or a cigweld 180 id steer clear of the china if thats what your doing. I prefer gas over gasless, getting a account with BOC isnt that bad and youd only need a small bottle anyway

[joshg123]

Drilled, tapped and welded the flange to that manifold yesterday,

Also been working on the ally welding, got back into it today and well Cleanlines is the killer, i can see where i was going wrong as i mentioned earlier, went and bought a staino wire brush and gave the ally a big scrub then cleaned with a R55 solvent and it worked a treat, i can finally get in the corner.

Still got to work on technique and heat but getting there, it would be awesome to have a foot pedal control, because i have to set a heat to not be at the start for 3 days waiting to pool but not be racing at the end, this weld was a little cold at the start and got it at a nice heat at the end

http://i6.photobucket.com/albums/y220/joshg123/000_0065.jpg

http://i6.photobucket.com/albums/y220/joshg123/000_0063.jpg

EDIT - the lhs of the ally photo is the start

Tips/Tricks?

Cheers

[DESAM8+PANIK]

Hey Josh does your tig have a High frequencey start it will help you start your pool when you weld ally and also stainless and mild steel to a certain degree

[matty12]

do you push or drag??

I push like mig welding,is that the right way??

I find it hard without a foot controller,its not easy for a amateur to get the balance right between waiting a week to 10 days to get the pool going or getting it far to hot at the end.

[iluv2moan]

push is right way

sounds more like amp rating your havign trouble with. foot pedal wont help that, pulse will

[joshg123]

Yeah Clint my welder has HF, i find starting the arc no problems, just setting the right heat to not spend 10 years at the start and then be road runner spec at the end a problem, thats where the foot pedal or hand control would be nice, to get going then turn down to have more control at end.

This welder doesnt have Pulse though, thats where it goes high to low amps yeh?

Cheers

[matty12]

mines got pulse but ive never used it.

[S133LTR]

Little bracket I milled up this morning.
http://i92.photobucket.com/albums/l13/KINGDS13/damopics005.jpg
http://i92.photobucket.com/albums/l13/KINGDS13/damopics006.jpg
http://i92.photobucket.com/albums/l13/KINGDS13/damopics007.jpg

[schnoods]

Looks Mint!

I probably woulda just used a bit of angle and notch n drill to suit, looks very flash.

[matty12]

i really think that bracket needs to be a little thicker,that'll never hold the weight of that plastic switch.

You also got the terminals around the wrong way to what we dicussed,do it again:)

[S133LTR]

termianls are the wrong way but the cable ends are at right angles so the cables go the way we wanted.

ps; its so think cause im tryn to get all the ally out of my shed

[thrtytwo]

heres a few things i've made at work;

my panel beating skiiiiilllz

http://i41.photobucket.com/albums/e283/thrtytwo/fab3.jpg
http://i41.photobucket.com/albums/e283/thrtytwo/fab2.jpg

oil catch can for a generator

http://i41.photobucket.com/albums/e283/thrtytwo/fab4.jpg

stainless canon for a go kart im making ;)

http://i41.photobucket.com/albums/e283/thrtytwo/fab5.jpg

[duste]

This isn't something I've done, but I thought it'd be respected in this thread anyway:

http://i103.photobucket.com/albums/m133/faithle55_2006/P1010002-1-1.jpg

From a Mazda BF 323 Rally Car - false floor, custom fuel tank, double wheel stand, roll cage and fibreglass battery box.

[joshg123]

Nice looking idea, but unfortunatly not practical for a australian application with those fuel fittings in a unfirewalled cabin.

[matty12]

Been doin this of late,trying to replace the nastie log manifolds that i originally made for the vl.

There is no exhaust theory in these at all,pipes are different lengths and everything but will be 100% better than what was in there.I have made and remade the front pipe six times over to get it to fit.Trying to fully weld it up to day but cant get all the joins,driven me nuts.

Anyway a pic.
http://i275.photobucket.com/albums/jj296/1uzvl/image.jpg

[iluv2moan]

looks mint matty - how many engine in/outs so far haha

[matty12]

none,but the engine has to be lifted to get it in,rack has to be dropped.Slip them in,put engine mount in,bolt up headers drop slightly bolt up mount then finally lower engine.

This is the easy side which i thought do do first to get the hang of it.Otherside has obviuosly a steering rack to contend with.I have less than 100mm from heads to chassis rails so everything is very tight.That set only clears chassis by 5mm.

Thank fuck toyota were smart enough to put the starter motor in the valley.

[joshg123]

Been working on my ally welding over the last couple of weeks and took on a water tank job for a work friend. Learnt a heap on this project, ie Cleanliness is everything on ally. Only stuffup i had was picking up a stainless rod by accident and trying to weld with that and scratching my head why it just spat black shit everywhere and i couldnt weld it.

Was a bit tricky on the corners as i had folded the main tank section, as well as folded each end. So there was 9mm of ally in places. Pressure tested it today and only had 2 small leaks on the corners at 100psi.

http://i6.photobucket.com/albums/y220/joshg123/000_0086.jpg

http://i6.photobucket.com/albums/y220/joshg123/000_0082.jpg

http://i6.photobucket.com/albums/y220/joshg123/000_0083.jpg

[NVIOUS]

Been considering splurging on a new TIG welder setup, looking for AC/DC w/ foot pedal control. I have no exp with a TIG, only basic skills with my MIG, so looking to muck round at home for practice. Any advice on best place to look & brand/models? Dont mind paying for a quality setup, just nothing too exotic, prob hoping to spend under 3k all up inc fittings, gas bottes etc. Prob also consider a basic plasma cutter eventually to make things easier. Not looking to weld anything too industrial spec, just general exhaust/body/fab work for the VN - hating my cigweld gasless MIG, too much splatter.

I know obviously BOC for the gas, fittings etc, but seem to be a bit more exp than others for actual welders etc.

[schnoods]

Try Burnback welding supplies in O'connor. They are one of the best with prices.

www.burnback.com.au

Also Western Welding Supplies in Spearwood.

For 3k you can a reasonably decent Tig, I would look at the CIG caddy type, with digital readout, AC/DC and pulse settings, 180am single phase, quite a nice piece of kit but would stretch the 3k.

But for something entry level you can find cheaper, simpler still works great.

[NVIOUS]

Cheers for the info mate, will go see them soon

[AGIT8D]

Few pics I've ripped off Metalcraft facebook to show some welding/polishing/fab work that might be of some interest to you lads

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs040.snc4/34338_112069945509081_100001182270867_71489_191770 9_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs062.snc4/34481_112071002175642_100001182270867_71499_485552 2_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs062.snc4/34481_112071012175641_100001182270867_71502_471596 _n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs195.snc4/38068_112072242175518_100001182270867_71508_349894 7_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs175.snc4/38068_112072248842184_100001182270867_71510_325342 9_n.jpg

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs175.snc4/38068_112072252175517_100001182270867_71511_126905 4_n.jpg

[180SXTCY]

dan thats looking mint, josh tells me its nearly out of the workshop so i can get my shitter down to him.. :)

[AGIT8D]

Haha yeah it is mate :) I didn't post up any pics of the drag car cause that's all secret squirrel but I'm waiting for that to get out so I can get mine in. You jumped the queue and stole my spot cause you're a customer haha :) The red rocket should come up trumps though, I'm lovin it so far!

[180SXTCY]

haha sorry man, im hanging out hard to get it into his shop and sorted. :P yeah the shitter should come up good

[4A10SHN]

You tested that tank to 100 psi hey? I don't think so bud!

[180SXTCY]

^ huh?

edit: ahh i get it now haha bit slow :)

[joshg123]

You tested that tank to 100 psi hey? I don't think so bud!

Yeah, what i now know as being a bit silly was to throw the compressors full measure of air in it. Compressor does 100psi so thats why i put that figure up. Unlike yourself, i am just learning this ally fab work.

[4A10SHN]

http://a.imageshack.us/img687/7736/photo8558876767.jpg

[4A10SHN]

Was down the shop till late, thought this was worth posting up...

[joshg123]

What welder do you have Josh?

[AGIT8D]

It's a water cooled Kemppi TIG that's all I know

[jaybee]

some rather nice welds there! fark.

[4A10SHN]

Yeah just got a Kemppi but solid state Millers are the winner...

It comes down to the operator in the end, doesn't really matter what machine it is. Even the cheap china ones do a decent job...

[mxracer]

do you push or pull the weld , eg in the pic shown did you got left to right or right to left , with which angle would the torch be top of handle leaning left or top leaning right ..

i trying to improve

Yeah just got a Kemppi but solid state Millers are the winner...

It comes down to the operator in the end, doesn't really matter what machine it is. Even the cheap china ones do a decent job...

[180SXTCY]

Yeah just got a Kemppi but solid state Millers are the winner...

It comes down to the operator in the end, doesn't really matter what machine it is. Even the cheap china ones do a decent job...

GTFO the net kent and get welding on my shitter :)

[Deke]

when you tig , generaly if your right handed torch in your right and wire in your left and i guess you push? you should move to the left if this is the case

[Chaotic]

I'm looking to have a crack at welding in the near future with next project, and would definitely recommend the following book as a good read for the basics. Goes thru and answers a lot of questions that have cropped up in this thread.

http://pitstop.net.au/view/products/page/query/plu/18463/

[34jzgte]

(edited for later)

[jaybee]

turbos on wrong side but wow!

i think i might change where im getting my intercooler piping done now!

[180SXTCY]

holy fucking bat shit man that is fucking mental!

edit: josh told me he was doing this for ya but didnt realise u were going that crazy! epic.

[34jzgte]

turbos on wrong side but

these Garret GT3540's will struggle for room on the other side ;)

[duste]

Holy fuck

[4A10SHN]

Yes Holly Fuck, Thought you were keeping this a secret Marco... Oh well yeah secret is slightly out of the bag!!!

This type of pipe work requires bulk man hours but the result is well worth it.

Cheers guys

MetalCraft Pty Ltd

[180SXTCY]

looks so nice josh :)

[4A10SHN]

I don't call it metalporn for nothing....

[180SXTCY]

hope mine comes out something like that ;)

[AGIT8D]

http://grfx.cstv.com/schools/ncaa/blog/catie_gibbons/lobster/lobster.jpg

[180SXTCY]

Lol dan. Lobster city.

[Deke]

so much got damn cutting!

[Mofo]

wheres the photo?

[4A10SHN]

Got taken down.... Too sexual

[Mofo]

not cool

[duste]

Just imagine some lobster bends - big ones, big sexy ones.

[4A10SHN]

not cool

They are still on the MetalCraft Facebook page thing

[AGIT8D]

They are still on the MetalCraft Facebook page thing

Facebook is broken!

[180SXTCY]

i was sporting a semi thats for sure.

[Magoogtir]

Few pics I've ripped off Metalcraft facebook to show some welding/polishing/fab work that might be of some interest to you lads

http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs040.snc4/34338_112069945509081_100001182270867_71489_191770 9_n.jpg



AHHH. Not long now and my baby will be back on the road haha

[AGIT8D]

Do a showcase jerk off :)

[Magoogtir]

Josh won't let me yet lol

[4A10SHN]

Add a DP man-goo

[matty12]

Just finished doing the other side, this was harder but was done in half the time and is alot better.
http://i275.photobucket.com/albums/jj296/1uzvl/Vl/IMAG0061.jpg
http://i275.photobucket.com/albums/jj296/1uzvl/Vl/IMAG0063.jpg
http://i275.photobucket.com/albums/jj296/1uzvl/IMAG0062.jpg


Sounds a little different to the logs i made and replaced, it doesnt pop and fart on back off now and should liven the engine up abit.Getting ceramic coated in the next few weeks as everything is millimeters of everything.

Next setup is blower bracket fabrication.

[180SXTCY]

^ nice work, get them cerami-chromed and they'll look balla.

[AGIT8D]

Clears all steering etc i assume? Always good to triple check before coating

[S133LTR]

pretty sure it was checked and road tested.

[matty12]

yeah road tested n shit to make sure it all clears, wouldnt make that mistake.


Also presure tested as well, its tough not too seening as everything that leaves our workshop is pressure tested.

[coFF33]

does anyone know

if i was to put a RB25 turbo onto my 1GGTE, with teh RB25 turbo dump pipe rotated for highmount use, if i could chop the dump pipe halfway down, then weld on my current 3" "down" pipe ( non stainless i think its mild ) to it ??

or can you not weld onto cast Nissan / Toyo dumps?

anyone know this ,

sorry if its a bit off topic...

[sutt0nk1]

you can weld cast but its no ideal plus you need to heat that shit right up befor you weld it.

[mitchy]

just buy a 3" dump, cheap cheap for nissan turbo's.

[coFF33]

Mitchy, from where?

[magic1]

Ok guys, here is my issue.

1. cat back exhaust is hks and i don't want to cut it up.
2. the dump is custom and has been ceramic coated so i don't want to just buy another dump.
3. I'm SOR either parmelia or myaree, don't want to have to go a million miles north

I there a welder on here that will be able to shorten the dump and make it fit.

I will take it off the car of course and pay, not expecting a free bee.

tristan

http://farm5.static.flickr.com/4151/5210755681_db2c636d34.jpg (http://www.flickr.com/photos/skyline25t/5210755681/)

[180SXTCY]

Josh from Metalcraft mlrd than likely be abke to help you out. However He is busy busy atm.

[Lonewolf]

wont the ceramic coating get cracked etc if you cut the dump pipe?

[gav]

Its at the other end of the flex joint. he wants to modifiy it to fit AFTER the end of the flex join, so it shouldnt crack or be affected by the mild heat it would receive in cutting/rewelding

[Deke]

that looks like a pingpingpingping of a job , if the flex join on the ceramic coated section wasnt there , then it would be as easy as just welding a flange on , but if you push that stainless one up it would be touching some were on the flexi join?

edit: lol sorry looking at it again , you can cut that flexi join out and push the pipe >> that way and cut it down alittle to get it perfect

[4A10SHN]

Ok guys, here is my issue.

1. cat back exhaust is hks and i don't want to cut it up.
2. the dump is custom and has been ceramic coated so i don't want to just buy another dump.
3. I'm SOR either parmelia or myaree, don't want to have to go a million miles north

I there a welder on here that will be able to shorten the dump and make it fit.

I will take it off the car of course and pay, not expecting a free bee.

tristan

http://farm5.static.flickr.com/4151/5210755681_db2c636d34.jpg (http://www.flickr.com/photos/skyline25t/5210755681/)

Easy - could be done on site

[4A10SHN]

http://img.photobucket.com/albums/v622/holdengemi/Photo1232.jpg

[4A10SHN]

http://img.photobucket.com/albums/v622/holdengemi/Photo1114.jpg

[adzmerc]

http://img.photobucket.com/albums/v622/holdengemi/Photo1232.jpg

Sweeeet Job mate!

[AGIT8D]

Where's the rest of the stuff?!? Make John angry and post it!

[4A10SHN]

That wasn't john's, that's another member off AL

[duste]

Lollll fuck don't post John's, not enough tissues here at work for me to deal with that!

[AGIT8D]

That wasn't john's, that's another member off AL

I know, I meant the rest of the stuff you've been working on.

[180SXTCY]

I know, I meant the rest of the stuff you've been working on.

LOl Dan u pingpingpingping joshie boy wouldn't do that to me :)

..i hope.

[180SXTCY]

Lollll fuck don't post John's, not enough tissues here at work for me to deal with that!

lol too kind sir.

[carlos spicy wener]

hey guys, im wanting to learn how to weld aswell.
have used a kempi 130A gasless MIG before, but couldnt get anything better than bird shit welds haha.

ideally i want to buy a cheapish welder and go from there.

are the cheap ARC welders worth a look? and what would you weld with one of these, just Mild steel?

[matty12]

Gasless is ya problem. We have a cheap arc at work, works alright and can pump out some alright stuff but the leads are far to short which is annoying.

[shifted]

Anyone here do plastic welding??

Need something plastic welded... please PM if you do!!

[thrtytwo]

Josh you use MIG or TIG for your ali work ?

[3BEPKA]

Josh you use MIG or TIG for your ali work ?

Looking at his work ....100% TIG

[thrtytwo]

Looking at his work ....100% TIG

was leaning that way but wasn't too sure, I don't do much ali welding and when I do I use a good MIG pulse set up. Lays pretty neat fat beads

[AGIT8D]

Josh uses a Kemppi TIG.

[thrtytwo]

I use one of these for most of my ally stuff at work, great welder!

http://www.silverwaterwelding.com.au/images/uploads/TPS2700.jpg

Fronius TP2700

welds like this ;

http://www.dpiaca.com/Fronius/samplewspecs.gif
http://www.dpiaca.com/Fronius/Schweissprobe_alu.jpg

(pics from google)

[ryanr32]

Josh has the same pulse mig but unless your doing a lot of welding on easy joins tig would be easier IMO. Especially on some of the pipes I've seen him weld plus if you can tig like he can why do anything else?

[OmEg_A7]

To the guys who have made turbo manifolds here, what are your secrets for cutting all the bends and making the 4-1 collectors.
Also how do you go about getting a weld in the middle of where all the pipes merge?

[thrtytwo]

Josh has the same pulse mig but unless your doing a lot of welding on easy joins tig would be easier IMO. Especially on some of the pipes I've seen him weld plus if you can tig like he can why do anything else?

true I suppose, We only make boxes, all long straight welds so MIG is faster

do tig stainless pipework however

[joshg123]

To the guys who have made turbo manifolds here, what are your secrets for cutting all the bends and making the 4-1 collectors.
Also how do you go about getting a weld in the middle of where all the pipes merge?

i just buy collectors from dumper king and exhuast, its more expensive but i dont have a bandsaw and it makes it a fair bit faster

[James_2007]

I use one of these for most of my ally stuff at work, great welder!

http://www.silverwaterwelding.com.au/images/uploads/TPS2700.jpg

Fronius TP2700

welds like this ;

http://www.dpiaca.com/Fronius/samplewspecs.gif
http://www.dpiaca.com/Fronius/Schweissprobe_alu.jpg

(pics from google)

used one of these when i did tech.
can weld a coke can to some 6mm plate very easy.

very nice machine

[ryanr32]

Not cheap either

[Miggy]

I'm after a cheap TIG set up can anyone recommend me something? And where do you get your gas from? BOC?

[Tocchi]

i have the TP2900 version at home :) it makes me look like a competent welder, but im not, the machine just makes it so easy


I use one of these for most of my ally stuff at work, great welder!

http://www.silverwaterwelding.com.au/images/uploads/TPS2700.jpg

Fronius TP2700

welds like this ;

http://www.dpiaca.com/Fronius/samplewspecs.gif
http://www.dpiaca.com/Fronius/Schweissprobe_alu.jpg

(pics from google)

[duste]

I'm after a cheap TIG set up can anyone recommend me something? And where do you get your gas from? BOC?

There was talk in this thread a while ago about some 125/150/175i from Cigweld? ~$1000 on eBay iirc.

[matty12]

alot of the unitig/BOC/cigweld tig welders are just rebadged china tig.s

I bought a china AC/DC tig, works alright on both steel and ally. The idiot behind the hand peice doesnt quite so well. The only real prob it has is sometimes it will arc inside the machine, i just touch the work piece with the tungstan, pull away then fire.

[AGIT8D]

To the guys who have made turbo manifolds here, what are your secrets for cutting all the bends and making the 4-1 collectors.
Also how do you go about getting a weld in the middle of where all the pipes merge?


i just buy collectors from dumper king and exhuast,

This. You can buy pre-fabbed stuff which would be recommended if you haven't had a crack before.

Here's one Josh just knocked up from scratch:

http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/225391_10150206465574681_671509680_7133150_7886205 _n.jpg

[180SXTCY]

Craig will be pulling himself over that (:

[duste]

Jelly

[4A10SHN]

Mid-mount are a KENT!

[4A10SHN]

http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/253458_10150209274684681_671509680_7154592_3851568 _n.jpg

[Deke]

hey josh , the thing that fucked me up the most when i made my mani was , which pipe and which join to weld first in a sequence so you could acsess all joins , how did you go bout this?

[4A10SHN]

Put my thinking cap on before I fired up the tig...

[duste]

The 'ole "magician's never real their tricks" routine!

[3BEPKA]

Nice job, BTW real man do it with 5P :p

[thrtytwo]

A bit OT, had a Fronius rep come to work today. Was having a chat with him and he was telling me they specially developed a mig process for Audi to use in the R8 for joining the gal floor pan to the alu chassis.

Apparently it welds the alu to the gal coated steel without distortion, damage to the gal or any other ill effects.

Was also telling me they can weld 0.32mm alu using 1.2mm wire, crazy shit

Fronius fo lyf yo!

[joshg123]

^ this.

was using a Fronius tig today, suprised me the diffence you can make to your weld with the options and the ability to adjust current mid weld..... im used to a slidey stick for amps and a ac/dc switch..... ahh me 80's welder

they are worth the money

[thrtytwo]

He told us a thing or two about our fronius migs as well which was really usefull.

Haven't got a fronius tig but he's bringing one in on Wednesday for us to have a play with. Lift off start sounds good.

[34jzgte]

CAD is a wonderful program,

http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/CADvsReal.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/CADvsReal2.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/3inchdumppipeclearance.jpg

[thrtytwo]

thats fuckin siic man, just that whole process of drawing it out before you fab it, very nice!!

keep us updated ;)

[jEstEr?]

Would something like this be good for the home newb like myself? Looking at doing a bit of stitch welding on my impreza and making the odd small part, also a rotisserie for the spot welding

http://www.sydneytools.com.au/shopexd.asp?id=14371

I did some calcs and it works out to 1mm-3.5mm thick steel, will that be thick enough for the sort of work I'm doing?

[joshg123]

Ive seen you weld haha

Only thing about those smaller machines, the duty cycle is a bit of a killer. At 130A, you can only use it for 1min out of 10. So it would be good for tack welding and some really light duty stuff, but you will struggle getting good peno on the thicker stuff.

In saying that, i use a 180A Lincoln at the workshop, good enough for welding 3m plate together etc.

[jEstEr?]

I was hoping you'd chip in ;)

I expected an answer like that. I want to buy something useful, not some chinese "200A" welder that can't get through a coke can. Half of me says the duty cycle wouldn;t be an issue but I can see once you get more efficient at welding it would start to get annoying


ps, 3m plate? shit thats a powerful welder :P

[magic1]

Ive seen you weld haha

Only thing about those smaller machines, the duty cycle is a bit of a killer. At 130A, you can only use it for 1min out of 10. So it would be good for tack welding and some really light duty stuff, but you will struggle getting good peno on the thicker stuff.

In saying that, i use a 180A Lincoln at the workshop, good enough for welding 3m plate together etc.

3m plate?

[jEstEr?]

something like this might be more of a winner, 25% at full noise (170a)
Bit more than I was hoping to spend though

http://www.ebay.com.au/itm/Cigweld-welder-transmig-175-ARC-MIG-TIG-NEW-/390233371604?pt=LH_DefaultDomain_15&hash=item5adbb8b3d4#ht_5723wt_1069

[thrtytwo]

Obviously more than you want to spend, but I had the luxury of using Fronius TIG machines today. a basic one goes for $1600, the next one up is $2400. Fuck me they are amaaazzzziinnng machines!

lift off start, auto gas on/off, give the torch a SLIGHT jerk and it slowly ramps down the amps and ends the weld, on the fly amp setting using a wheel on the torch. 4 levels of pulse, a PERFECT arc, doesn't stray at all!! even with a shitty blunt tip. BUT if you want to, you can set it to automatically stray the arc side to side, or "weave"

all in such a tiny little package! I was seriously TIGing like a robot, I cut off a few welds I did to kep just cos they were soo good!

<-- total fronius fan boy

[Torquen]

OK guys, I've got a question regarding altering a bolt in 1/2 cage.

Currently not fitted in my 13 (non-sunroof model) due to my head already touching the roof (with a helmet on). Now I know that by getting a low mount bucket seat with side mounting brackets will drop me up to 1.5inches (aka fix the problem) but when I install the 1/2 cage my head will once again hit the roof/crossbar.

Now since buying a bigger car isn't really an option I was wondering if I could alter my 1/2 cage's crossbar so that it didn't come near the drivers head area.

This is the type of cage:
http://i546.photobucket.com/albums/hh406/jshakersgmailcom/t_20-91-330-43065f5272e0c83c35b5fba1ebb8d0ec.jpg

This is what I thought may be possible:
http://i546.photobucket.com/albums/hh406/jshakersgmailcom/sfsdfdsfd.jpg

If anyone has any other ideas feel free to chuck 'em up :)

Cheers, Jesse.

[joshg123]

Of course its possible, it would however comprimise the cages integrity. And you would obviously have to cut and weld that section in, which is against regs. And if the rest of the cage complied to cams bolt in requirements, that modification would then turn your cage into a bolt in monkey bar set.

I guess it depends on what your using it for, a modified cage is better than no cage in my opinion, but im not sure if scruitineers will see that the same way.

Personally id try and get that seat hard on teh floorpan, and push came to shove get the floorpan modified rather than comprimise the cage.

[mc68]

id run no cage at all rather than put a section like that in...

in a roll, where do you think its going to bend? where is your head in comparison to that?

my 2c :)

[lambchops]

OK guys, I've got a question regarding altering a bolt in 1/2 cage.

Currently not fitted in my 13 (non-sunroof model) due to my head already touching the roof (with a helmet on). Now I know that by getting a low mount bucket seat with side mounting brackets will drop me up to 1.5inches (aka fix the problem) but when I install the 1/2 cage my head will once again hit the roof/crossbar.

Now since buying a bigger car isn't really an option I was wondering if I could alter my 1/2 cage's crossbar so that it didn't come near the drivers head area.

This is the type of cage:
http://i546.photobucket.com/albums/hh406/jshakersgmailcom/t_20-91-330-43065f5272e0c83c35b5fba1ebb8d0ec.jpg

This is what I thought may be possible:
http://i546.photobucket.com/albums/hh406/jshakersgmailcom/sfsdfdsfd.jpg

If anyone has any other ideas feel free to chuck 'em up :)

Cheers, Jesse.

i had the same issue with my s13. with the half cage installed the main hoop bar sits a bit further back than your helmet so it didn't reduce my head room at all

[Torquen]

Hmmm, righto well maybe best bet is see how I fit in with a lower seat first then if it's not good look at other options.

[-Luke-]

Gurney bump it and mod roll bar to suit?

<a href="http://www.flickr.com/photos/vikalina/2806337521/" title="GT40 Roof by Vikalina, on Flickr"><img src="http://farm4.static.flickr.com/3007/2806337521_ae15fa5627.jpg" width="375" height="500" alt="GT40 Roof"></a>

[4A10SHN]

Can bend you up a top hoop with a section out for your helmet, what's the od of the original tube? (to the XX.XXmm)

[Torquen]

Standard roll bar size... 40mm AFAIK.

Mash it with a hammer down to 30-20mm where it fowls on the helmet??

[Tocchi]

hey guys, im looking at learning tig welding for stuff for work etc... anybody got hookups to Fronius gear?
already have the unit (TPS2700/2900) ... just need the tig gear.

[-Luke-]

Are the fronious consumable different to your average miller/lincoln/kempi Tig?

Whats a second hand Lincoln Invertec PC100 worth? Try to pick one up from Ross for around the 600 mark but missed out? Was an absentee bid so Im not sure if I missed out it they just didnt register the bid?

Picked up a Chinatig this week, if it lasts long enough to build me a set of cooler pipes and a manifold I'l be happy!

http://i265.photobucket.com/albums/ii201/lukehidderley/th_photo-2.jpg (http://s265.photobucket.com/albums/ii201/lukehidderley/?action=view&current=photo-2.jpg)

[34jzgte]

Merge baby, engineering joint did the welding for a carton.

http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/Mergecollector.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/006-2.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/003-3.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/003-2.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/005-1.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/007.jpg
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/006-1.jpg

[-Luke-]

Looking good mate, those welds look very nice! Did they also cut your merge pipes? where are/did you source your black pipe and elbows?

[duste]

AutoCAD for 3D work? You're obviously the most patient man in the world haha.

[Scaf]

It seriously took me for-fucking-ever to cut and get my merge pipes to work, biggest head fuck ever.

[34jzgte]

Looking good mate, those welds look very nice! Did they also cut your merge pipes? where are/did you source your black pipe and elbows?

I got them from Valfit.com (www.valfit.com.au) cheapest prices around without trade rates, total was about $300


I pre cut everything my self before hand even the mergers, got all my measurements to 0.00mm with digital calipers, i cut it all by hand with a 1mm blade, you can get wraparounds from CAD and use them to make mergers, takes the trial and part error out.
http://i989.photobucket.com/albums/af16/34jzgte/CAD%20designs/005.jpg

[34jzgte]

AutoCAD for 3D work? You're obviously the most patient man in the world haha.

that wasn't to much trouble, its when you do things like full cars it gets bit much.

[Mofo]

whered you get the flange plate for the head if you dont mind me asking.

[34jzgte]

whered you get the flange plate for the head if you dont mind me asking.

straight line specialties.

[thrtytwo]

hey guys, im looking at learning tig welding for stuff for work etc... anybody got hookups to Fronius gear?
already have the unit (TPS2700/2900) ... just need the tig gear.

TPS2700 is a great MIG, but only a very basic scratch start when used for TIG. If thats all you need then its fine :D We buy our Fronius stuff from burnback, they're round the corner from xspeed

http://www.burnback.com.au/contact.html



Are the fronious consumable different to your average miller/lincoln/kempi Tig?

no, all normal consumables



when the fronius rep was in the other day he was telling us their latest show demo is to vert down weave a 25mm gap in 3mm plate. Fucking mind blowing, reckons no other manufacturer can do that past an 8mm gap

[DanWA]

http://www.awelco.com/_download/tecnicaldata/11700_tec.pdf

Any good for $450 ?

[4A10SHN]

Looks good for automotive Dan!

[jEstEr?]

where from?

[crabman]

Quick Q, got an ali plenum that needs throttle body flange tacked on for me to test fit, then welded on completely once it fits up ok.

Anyone canningtonish area got the gear at home willing to do this for a carton or know of a business welshpool/kewdale/canningtonish area that will do it cheap. I know of LF performance but also heard I would need to mortgage my house to get them to do any ali welding :P

[-Luke-]

Q regarding TIG lenses, using a (http://www.protoolsnsafety.com.au/nuweld-automatic-welding-helmet-p-242.html) NuWeld hemlemt Din3 when Light Din11 when dark Din16 UV/IR protection have done about 4hrs ally tig in the last 3 days and now have all symptoms of a flash and a blister on my eyelid??

DIN16 should cover TIG?

Oh and any good local sources for T3 6cyl merge collectors?

[crabman]

http://www.ebay.com.au/itm/Lincoln-Magnum-100SG-Spool-Gun-K2532-1-/270745641948?pt=LH_DefaultDomain_0&hash=item3f09b2a3dc

When they say this only fits listed lincoln welders, I am guessing I can still modify my unimig to make it work?? Surely it just uses the welders gas solenoid, diverts wire feeder motor current to handpiece and main welding lead to new handpiece aswell.........

Was talking to a mate about how the plenum needed welding and he mentioned just buying one of these, would pay for itself in throttle flange and one cooler pipe if it would work with my welder.

[Rich]

Quick Q, got an ali plenum that needs throttle body flange tacked on for me to test fit, then welded on completely once it fits up ok.

Anyone canningtonish area got the gear at home willing to do this for a carton or know of a business welshpool/kewdale/canningtonish area that will do it cheap. I know of LF performance but also heard I would need to mortgage my house to get them to do any ali welding :P

had them do exactly the same job for me a while back. wasnt too expensive from memory.

[4A10SHN]

Mark it with a pen and I'll do it for you :)

[crabman]

Already sandblasted, deburred and marked ready to go, but your in Mandurah are you not??

[4A10SHN]

I sure am, sandblasted? What the? Was it powder coated?

[crabman]

Na, just had marks and runs of paint on it so I just put it in the sand blaster (with glass beads) at work. Will try and swing into lf and get it tacked tomorrow and see how I go. Your a half day trip away :P

Your a pro, do you think I can adapt that spool gun to fit a 175A unimig??

[pazza]

Guys with TIG weld`n what gas is used when weld`n...
1) mild steel
2) stainless steel
3) aluminium

and is there such a gas as " general purpose gas" ??

[Tocchi]

hey guys, im looking at learning tig welding for stuff for work etc... anybody got hookups to Fronius gear?
already have the unit (TPS2700/2900) ... just need the tig gear.


Are the fronious consumable different to your average miller/lincoln/kempi Tig?


TPS2700 is a great MIG, but only a very basic scratch start when used for TIG. If thats all you need then its fine :D We buy our Fronius stuff from burnback, they're round the corner from xspeed

http://www.burnback.com.au/contact.html

no, all normal consumables

when the fronius rep was in the other day he was telling us their latest show demo is to vert down weave a 25mm gap in 3mm plate. Fucking mind blowing, reckons no other manufacturer can do that past an 8mm gap

ok just had to google scratch start Tig
"scratch starting is just like Stick.. You should scratch on a piece of copper to start, so you dont contaminate the tungsten.. With foot pedal control it is easy to get used to it with just a small current, then you just push down harder to get the desired welding current..

Yes my welder is scratch start for now..One day soonish I am going to build a high frequency arc starter.. it makes a high voltage high frequency arc that jumps the gap so you dont have to scratch start"
^ that's correct?
if so, yeah i think that's all ill need, as im just trying to learn each method :)

i got my Fronius gear from Burnback too. :)

haha i love filling in gaps with the Fronius -- usually because i "eye measure" it and blow a hole in it, thus having to fill it in.


guys with gas bottles, is it possible to own them outright?
i was paying $64/month for 4 large bottles (the 1.6m long ones?), 2x oxy/acet 1x argon 1xsteel mig, so we took them back to Air Liquide as we werent using them that much to justify those costs.
pretty much chasing an outright sale / pay for what you use, and maybe half size bottles.

[mr m00se]

I dont think you can ever own bottles outright, even at work they have to rent them of BOC and they have prob 50+ tall bottles of Argon and a big He bank.
I think if you rockup with a random bottle they refuse to fill it because its too much of a risk for them (Kaboom and such)

[-Luke-]

Tocchi, talk to airliquide/boc about long term rental drops the price by around 10% p/year but if you go on hols for 3 months and wont use the gear you still gotta pay. Cheapest way is to get it in for a job, use it up and fark it off so you dont pay the rental.

Boc are onto this tho a "D" Argon is $123 to fill (2m3 of gas) a E is $145 and is 4.1 cubes!$22 more for "twice" the gas.

[Tocchi]

thanks guys. luke, so i could go to Air Liquide (have an account with them) and hire a bottle, use it for a week or so, then take it back, and it's all ok? / no contract agreement for a minimal rental time period?
they don't mind? would i be paying for a months rental in the above scenario?

[-Luke-]

that how I run it with Boc, went Boc as they are closer to me than Airliquid (who where marginally cheaper)

If you on a long term contract even if you return the bottle you still pay the rental.

If your on day rental you can do just that use it up and return it. You dont pay rental on the empty bottle.

Boc also lock you into the bottle size, IE if you are using a E size Argon and decide to change to a D size you will still pay for the E size until the contract expires

[Tocchi]

nah no contract involved, just have an account.
if i dont use all the gas, i have to pay rental on bottle?

[-Luke-]

Yup so even if you take it back 3/4's full you wont get that back. Rental for my F size argon/argo shield is $15ish a month

[Tocchi]

ok so ill just empty it all out into our lovely atmosphere then :p

[-Luke-]

"This is composition of air in percent by volume, at sea level at 15°C and 101325 Pa.

Nitrogen -- N2 -- 78.084%

Oxygen -- O2 -- 20.9476%

Argon -- Ar -- 0.934%
Carbon Dioxide -- CO2 -- 0.0314%

Neon -- Ne -- 0.001818%

Methane -- CH4 -- 0.0002%

Helium -- He -- 0.000524%"

Right back where it started from :P


I have my flow meter set @ aprox 8ltr/min for the Tig I just bought, bottle has dropped from 200bar to aprox 90 bar since monday probably about 7 hrs welding time all up. You'l be surprissed how fast you use it!

[RS_Gav]

Quick couple of pics of the frame I am welding up for to hold the new 7"x14" mini-lathe I just bought. Nothing real exciting or challenging but fark I love the look of a neat TIG weld!
I have a few small project to getting started on for the new lathe. Trying to find as much info on them as possible in the mean time. Anyone else using a mini-lathe?

http://i26.photobucket.com/albums/c146/Big_Gav/IMG_1698.jpg

http://i26.photobucket.com/albums/c146/Big_Gav/IMG_1699.jpg

http://i26.photobucket.com/albums/c146/Big_Gav/IMG_1700.jpg

[S133LTR]

Got a link to what youve bought dude?

[RS_Gav]

This one mate.

SIEG C3 - http://www.siegind.com/product.php?id=17

It's China all the way but it does rate highly on a lot of forums. It will be fine for what I want These guys make them and then sell them on again to other companies to rebrand and sell.

[magic1]

looks like the welder is a little hot gav

[Risk10k]

Quick couple of pics of the frame I am welding up for to hold the new 7"x14" mini-lathe I just bought. Nothing real exciting or challenging but fark I love the look of a neat TIG weld!
I have a few small project to getting started on for the new lathe. Trying to find as much info on them as possible in the mean time. Anyone else using a mini-lathe?

I've a little more experience with this one;

http://farm3.static.flickr.com/2484/3766072997_49fe98e014.jpg

Almost Identical to the old mans one, but essentially the same. You can turn up a drive shaft quite easily :D. Only disadvantages is its not a self centring spindle so everything gets measure by a rotation tool (can't think of the name off the top of my head!). Fucking fantastic tool, be careful though - you'll start turning up your own nothenele bushes :)

[-Luke-]

looks like the welder is a little hot gav

+1, Much undercutting

[RS_Gav]

I've a little more experience with this one;

http://farm3.static.flickr.com/2484/3766072997_49fe98e014.jpg

Almost Identical to the old mans one, but essentially the same. You can turn up a drive shaft quite easily :D. Only disadvantages is its not a self centring spindle so everything gets measure by a rotation tool (can't think of the name off the top of my head!). Fucking fantastic tool, be careful though - you'll start turning up your own nothenele bushes :)

Yer that is very cool! Bushes, sleeve inserts and other little bits and pieces is what I bought the C3 for. Should be good fun.


looks like the welder is a little hot gav

+1, Much undercutting

Points noted gentlemen.

[S133LTR]

http://farm3.static.flickr.com/2484/3766072997_49fe98e014.jpg

Thats a tiny spindle bore for a machine of that length! What do you do on it Risk10K?

RS_Gav looks like a nice little machine.. with out knowing much about what your doing I would suggest try to keep the frame as rigid as possible across the rotational axis of the chuck because when doing work that small you need decent RPM to get good results and if the frame isnt pretty sturdy it will vibrate and that will transfer into the job..I would definitely consider bolting the frame to the floor and the machine to the frame if possible. Should be good for ally/mild steel/nylon/plastic etc... but Ive always found you need to be really light with cut depths on anything like stainless/high tensile with machines that small.

If you need a hand to check it all over when you set it up im not working atm (ie bored as fuck) and have all my tools measuring gear at home.. might be able to help??

[cplagz]

+1, Much undercutting


looks like the welder is a little hot gav

Rookie mistake, clearly left it on the same settings he used to tack it together.

[joshg123]

Out of interest, does anyone know what that cnc mill looking thing is worth?

I have a little lathe bigger than that one, but smaller than a full size shop lathe. Thought id have a million tasks to do with it but have never used it haha

[turael]

Hello gents,

I'm looking at a TIG, my budget is about 2k (which has to include helmet, foot control, some tungsten, gas bottle). Been looking at the unimig 200 (here for $1400 (http://www.gettoolsdirect.com.au/welders/unimig-200amp-240v-ac/dc-tig-kumjr200ac/dc.html)) and the tokentools 200 (here for $1400 (http://tokentools.com.au/prod28.htm)). This would give me enough $$ for the rest of the stuff too.

I've heard good things about the tokentools welder, but nothing about the unitig.. but obviously the unimig is a brand name unit. Someone further back in the thread mentioned unimig was often china rebadged? I know for a fact that the token 200 is made in china, but to Aussie specs, the unit is designed by some engineer bloke in NSW.

So what do, is there a better one for this price range, and has anyone used either of these welders?

cheers

[-Luke-]

I have a krieger WSME-200 which is another incarnation of the Uni-Tig. Def china spec, but does a good job once its setup properly and your accustomed to it. I did get mine checked over by my old man who's a sparky with alot of welder service experience. We found a few little bits and pieces that could cause issues in the future (loose terminal, wiring not secured correctly etc etc).

be careful with your choice of helmet. If you go auto darkening make sure it specifies suitable for low amp tig operation. I got burnt (litterally) by a Uni-Weld auto darkening helmet. Any amperage under 20amps makes it slow to react. Not slow enough to notice but slow enought to give me blisters on my eyelids!

[turael]

Thanks for the heads up. what's a good helmet? I've used a lincoln dominator V1 (http://www.weldingsupplies.co.nz/shop/Safety+Equipment/Dominator+V1+Welding+Helmet.html) for hours and hours of mig welding and that's been 100% fine, but it's not mine and they're pretty expensive it seems...

[-Luke-]

I now have a spherion mate. Look them up. Most helmets are fine for the higher amp tig stuff. Its the lower amp stuff that gets you!

bit of a read

http://forum.weldingtipsandtricks.com/viewtopic.php?f=2&t=220

[cplagz]

Out of interest, does anyone know what that cnc mill looking thing is worth?

I have a little lathe bigger than that one, but smaller than a full size shop lathe. Thought id have a million tasks to do with it but have never used it haha

You can get CNC kits for many lathes, what model/brand is yours?

[thrtytwo]

IMO the best helmets are speedglas, but you pay for them. A lot of different brand helmets will offer similar specs, similar functions. But I find speedglas have the best build quality, and excell at what they're made for. Also have a great aesthetic, not like most generic helmets. Not that it really matters :P

Mine was about $620, plus another $110 for a rear apron, but that's the best one they make with the largest lens area.

[-Luke-]

Agree, but unless you a rich pingpingpingping a Speedglas is a bit OTT for the average bloke to use at home IMHO

[thrtytwo]

Agree, but unless you a rich pingpingpingping a Speedglas is a bit OTT for the average bloke to use at home IMHO

this is true I guess, I'm a boilermaker so need good shit for day in, day out, welding.

[-Luke-]

Agree +1, A mate of mine is a boily for Worsley. Does alot of HP piping ravs about his speedglas helmet, he also has the cooling/filter hood. Nice unit. Big $'s but!

[S133LTR]

You can get CNC kits for many lathes, what model/brand is yours?

Got any links? Curious to see how one would fit a multi tool turrent set up to a standard lathe/mill.. Any sort of cnc machine with out multi tooling would be a waste of time wouldnt it?

[cplagz]

Got any links? Curious to see how one would fit a multi tool turrent set up to a standard lathe/mill.. Any sort of cnc machine with out multi tooling would be a waste of time wouldnt it?

Nothing specific - I only know about the kits as I keep link spamming RS_Gav the ones for his lathe ;)

[zeroyon]

Need some help. Have two custom sway bars from whiteline/Selby - neither fit due to my large sump and 26.

No one i can find local wants to modify them. One place will make from scratch if I provide the material.

Any idea ....

A> What steel I should use ?
B> Where can I get this steel in 27mm ?

[-Luke-]

You cant just use off the shelf steel. It needs to be heat treated correctly otherwise it will twist and stay twisted.

The bar would need to be formed and then treated.

[Skitzo]

What about modifying the links?

[3BEPKA]

Not slow enough to notice but slow enought to give me blisters on my eyelids!

lol,Uni-Weld is probably china made cheap shit.If you want good helmet get SpeedGlass 9002x, big viewing area,sensitivity adj.(good for when you work in low light),9-13 shades,delay adj. etc. also comes with optional Adflow unit which is great if you have coin (about $1600 for the kit).
In my opinion every kunt that does welding for living should have one. On the other hand if you just playing around in your garden shed,then just get $20 flip up screen el cheapo which wont blister your eyelids for sure.

[thrtytwo]

I've got a 9100XX, huge viewing area, as well as side windows. I love it :D

[crabman]

After a plasma cutter. Anyone got elcheapo china ones of eBay and had any bad luck??

http://www.ebay.com.au/itm/3-1-MISHTO-DC-INVERTER-WELDER-TIG-ARC-PLASMA-CUTTER-/360389042286?pt=AU_Welding&hash=item53e8dc606e

Had a mate using one that some guy bought of eBay for around the same price and cant seem to fault it. Couldnt remember the brand on it though.....

[kiasu]

anyone know of a good alloy welder? bought a 2nd hand pwr radiator and found out the hard way that it had a hole in the core near the bottom tank.. so needs to cut off the bottom and weld the inside.

[thrtytwo]

Something I made at work today. Nothing too shiny/fancy, but I had to design it as I was going and was pretty happy with how it turned out!

Spare wheel lock for mine spec ute.

http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0758.jpg?t=1315577539
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0759.jpg?t=1315577502
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0760.jpg?t=1315577467
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0769.jpg?t=1315577109
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0768.jpg?t=1315577153
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0770.jpg?t=1315577074
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0765.jpg?t=1315577261
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0764.jpg?t=1315577297

[Skipmaster J]

I keep looking at that and still have no idea how it works. You just designed and fabbed that up on the fly? Nice work.

[wormbo2]

Patent that shit son!!
Could make you some kesh if you make em quick enough!!

[thrtytwo]

I should of mentioned the back plate (the one with the nut welded to it) gets welded to the ute. The one with all the pins on it is just to locate and lock into the wheel. You then get the wing nut semi tight, and spin the wheel round until the wing nut is in the right spot to drop in the locking pin, and padlock together.

[crabman]

Im trying to figure out whats wrong with an extra stud with a hole in it for a padlock to go through. Was it for big company that wouldn't notice the extra dollars in labour?? :P

My hong-kong special plasma/tig thing rocked up this week. Hopefully pull my finger out next week and get the adapters I need to hook up my argon bottle and see how the tig welding goes. Not expecting much but, and for the price I'm more than happy for it to just sit there and be a plasma cutter only.

[thrtytwo]

Im trying to figure out whats wrong with an extra stud with a hole in it for a padlock to go through. Was it for big company that wouldn't notice the extra dollars in labour?? :P

not 100% sure what you mean, but if you mean what I think you do, then ...

that would just lock the clamping plate to the wheel, I had to stop the lug nut from turning so it couldn't be unscrewed

[Oversteer]

After a plasma cutter. Anyone got elcheapo china ones of eBay and had any bad luck??

http://www.ebay.com.au/itm/3-1-MISHTO-DC-INVERTER-WELDER-TIG-ARC-PLASMA-CUTTER-/360389042286?pt=AU_Welding&hash=item53e8dc606e

Had a mate using one that some guy bought of eBay for around the same price and cant seem to fault it. Couldnt remember the brand on it though.....


Don`t expet too much from that china combo, hope it works ok for you, I bought one about 18 months ago mma, plasma, dc&ac tig(spent more than that)..... its chinerific ! Tig works ok, ac is a bit rough but it works...plasma cut is gay, very rough and hard to start...chews through tips !! If it didn`t work ok as a tig I`d give it away !

Anyway I really need a plasma cut(need to cut shit with-out the heat of oxy that hardens shit and breaks all my lathe tools!) so I bought this a couple of days ago...I just couldn`t drop 2k on one but I tried to get the lastest pilot arc(cut thru rust, paint etc) with the best torch ...I hope it works ok !

http://www.ebay.com.au/itm/110696055781?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649

[crabman]

not 100% sure what you mean, but if you mean what I think you do, then ...

that would just lock the clamping plate to the wheel, I had to stop the lug nut from turning so it couldn't be unscrewed

Ahhh, so this clamps the bolted on spare wheel?? That makes more sense to me, I though the wheel sat on and this secured it only. Do they have a drama with the spares wheel nuts going missing??

I always give china a shot first as you never know what you may get for your money haha. After this I will get something decent that will last me for a lifetime, but who knows, this thing might last 10years and get me to an age where I just enjoy golf :P

[thrtytwo]

made a couple of random one off items at work, no drawing, just made it as I went.

First thing was rotating/locking mechanism for a leg on the back of a huge ass trailer with a huge ass geni on it

http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0825.jpg?t=1325840558
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0826.jpg?t=1325840509
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0830.jpg?t=1325840274
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0831.jpg?t=1325840222

As you can see on the rear shot, it only turns a 1/4 turn. So it can only go to the leg down, or leg up position. All made from bits of pipe and 5mm plate and a 1" socket cut in half. The 70mm pipe inside the 80mm pipe had about 2mm clearance so I welded 4 runs around the length of it and then machined them down to have only 0.5mm clearance, turned much smoother then.

Second thing is a massive oil catch can for the aforementioned huge ass geni. Pretty simple, just a baffle inside, the chamfer on the rear is just to clear an existing bracket where I'm mounting it. It's hard to see in the pic, but the corner with the tap on the bottom is the lowest point, I cut up 5mm across the front face, and then up another 5mm across the depth to the back corner so the whole bottom is angled slightly to the tap.

http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0827.jpg?t=1325840466
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0828.jpg?t=1325840409
http://i41.photobucket.com/albums/e283/thrtytwo/IMAG0829.jpg?t=1325840350

The main part of the body is one pice bent round to make a box. Then the top and bottom are both single pieces. All TIG welded 1.6mm carbon steel

[JBAE]

nothing better than good fab work!!!

[Niva]

Could be wrong thread, but who would you go to for getting something like stronger half shafts in there wasnt any available after market?

Also, making up stronger control arms, again no after market available

[Passage GT]

thrtytwo is obviously a boily, if you had dimensions i'm sure he could knock anything up, whether he'd be willing to or has a workshop is another matter.