Welding bevel washer
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  1. #1
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    Welding bevel washer

    So i need to weld mallebale cast iron bevel washers to the flange of C channel, then weld the nut to the washer. I have to weld these parts since they will be inaccessible to put a wrench on them. Normally if it was in a low stress aplication I would MIG the cast washers, but this time its alot of force on the washers. Im not sure if I can get away with a couple good sized MIG tacks or even some 7018. I just don't want to have the washer crack and fail due to the welds since it will be a major PITA to re-access the washers/nut.
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  2. #2
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    Re: Welding bevel washer

    What you could do is make your own bevel washers by cutting from the flanges of channel iron. Just drill your holes before cutting. If there is that kind of stress on the washers, that would be more sound than malleable ones.

  3. #3
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    Re: Welding bevel washer

    Why did I never think of making my own washers from channel sometime the simplest thing you can overlook

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  4. #4
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    Re: Welding bevel washer

    I had a 10" S beam that I had to bolt onto plates, and didn't have bevel washers. Cutting them is what I did. Worked out good. Is this on your press? Been following it some on GJ.

  5. #5
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    Re: Welding bevel washer

    Yep its on my press

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  6. #6
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    Re: Welding bevel washer

    If you can find some threaded rod nuts long enough, just cut them in half at the appropriate angle and weld.
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  7. #7
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    Re: Welding bevel washer

    You will require a mag drill to drill bolt holes in c channel prior to cutting beveled washers from it.
    Are you sure these are cast iron?
    Beveled washers are very common with the ironworker trade and structural steel erection. I've never seen cast iron beveled washers.
    Jason
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  8. #8
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    Re: Welding bevel washer

    Quote Originally Posted by snoeproe View Post
    You will require a mag drill to drill bolt holes in c channel prior to cutting beveled washers from it.
    Are you sure these are cast iron?
    Beveled washers are very common with the ironworker trade and structural steel erection. I've never seen cast iron beveled washers.
    Why would you need a mag drill? I drilled the ones I made on a regular drill press. Just drill them before cutting. If I recall the metal is a little sketchy on the washers, but I don't think they are cast.

  9. #9
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    Re: Welding bevel washer

    Well here's a picture of some washers that are the same material as my washers, nut sure why it matters but yes I do Have a mag drill.
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  10. #10
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    Re: Welding bevel washer

    I should add I did spark test them and they did'nt spark like steel or even cast steel.
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  11. #11
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    Re: Welding bevel washer


    f150skidoo


    Not all bolt-houses are the same - nor is the quality of bevel washers.
    Your [photo] example is all I have ever seen at industrial-retail outlets.

    For: a 'know/spec product', you have to go to a real bolt-house. Said
    houses
    : are not generally open to the public, require an account, only
    accept phone orders, may or may not - have will-call; and they want to
    sell in keg quantities.

    They have all of the goodies - but small quantities can be hard to get.

    Search the sights that project type specifications . . .
    http://www.google.com/search?q=bevel...HTDjBDUQ_AUIBA

    How many do you need? If tooled, it may [will] be easier to drill & rip a
    channel flange than to source a small quantity of spec. material.


    Opus

  12. #12
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    Re: Welding bevel washer

    Just cut washers from channel legs, drill and tap them and then there is no more weld on weld

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  13. #13
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    Re: Welding bevel washer

    Quote Originally Posted by f150skidoo View Post
    I should add I did spark test them and they did'nt spark like steel or even cast steel.
    If you've got a spare one you could do a "weldabilty" test. Lay one on a piece of scrap and run a fillet down one side and then hammer a cold chisel in from the opposite side and see how easily it'll break off. Who knows? You might find they'll weld OK.

  14. #14
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    Re: Welding bevel washer

    https://www.fastenal.com/products/details/33345
    https://www.fastenal.com/products/details/33883
    http://www.almabolt.com/pages/catalo...quarebevel.htm
    Malleable or steel, galvanized or plain.
    Although I like the idea of just drilling and tapping a piece of square stock and cutting the correct angle on it because you can make it as thick as you want it for maximum thread depth.
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  15. #15
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    Re: Welding bevel washer

    I'd weld on a piece of mild steel to the inside of the channel, then drill and tap from the other side. No need to cut any angles, just weld it on. Nothing to warp as you drill and tap after welding from the opposite side.
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  16. #16
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    Welding bevel washer

    Quote Originally Posted by M J D View Post
    Why would you need a mag drill? I drilled the ones I made on a regular drill press. Just drill them before cutting. If I recall the metal is a little sketchy on the washers, but I don't think they are cast.
    I'm guessing he needs holes for 3/4" or 1" dia bolts? This will require a 13/16 or 1 1/16" holes. How many washers does he need, 4 or 40? You drill these on a drill press? A mag drill with an annular cutter bit would make quick work of this and be much safer.
    If he only needs a couple washers for some small bolts, yes, he could just work them down with a grinder/flapper and drill them on a drill press. That would be the cost effective way. But for bigger bolts and a lot of washers, different story.


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    Last edited by snoeproe; 01-08-2017 at 10:29 AM.
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  17. #17
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    Re: Welding bevel washer

    Quote Originally Posted by snoeproe View Post
    I'm guessing he needs holes for 3/4" or 1" dia bolts? This will require a 13/16 or 1 1/16" holes. How many washers does he need, 4 or 40? You drill these on a drill press? A mag drill with an annular cutter bit would make quick work of this and be much safer.
    If he only needs a couple washers for some small bolts, yes, he could just work them down with a grinder/flapper and drill them on a drill press. That would be the cost effective way. But for bigger bolts and a lot of washers, different story.


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    What's the big deal with a drill press? Pilot hole, and final drill. While I have 2 different mag drills, they are often not needed. Kind of like a $1000 dollar solution for a 10$ problem.

  18. #18
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    Re: Welding bevel washer

    Quote Originally Posted by HT2-4956 View Post
    If you've got a spare one you could do a "weldabilty" test. Lay one on a piece of scrap and run a fillet down one side and then hammer a cold chisel in from the opposite side and see how easily it'll break off. Who knows? You might find they'll weld OK.
    So I ended up doing this test welding the washer to 1/4" plate with a full fillet weld down one side of the washer. With 5 hits on a chisel the washer broke in half.

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  19. #19
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    Re: Welding bevel washer

    Quote Originally Posted by f150skidoo View Post
    So I ended up doing this test welding the washer to 1/4" plate with a full fillet weld down one side of the washer. With 5 hits on a chisel the washer broke in half.

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    That's not good, I would bet just over tightening one would probably break it over time. Hard to believe they would sell such crap.

  20. #20
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    Re: Welding bevel washer

    Ya I know, i was looking through my off cuts and C3x4.1 flange is the exact same size as the 1/2" bevel washers so ill just use the channel and make my own washers out of mild steel.

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  21. #21
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    Re: Welding bevel washer

    Cool, you won't have any worries with those failing.

  22. #22
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    Re: Welding bevel washer

    McMaster-Carr has bevel washers in steel. 5 for $10. https://www.mcmaster.com/#standard-washers/=15u7a26
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  23. #23
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    Re: Welding bevel washer

    Quote Originally Posted by Oldendum View Post
    McMaster-Carr has bevel washers in steel. 5 for $10. https://www.mcmaster.com/#standard-washers/=15u7a26
    Betcha can't make em for $2 a piece.... unless your time is free

  24. #24
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    Welding bevel washer

    Quote Originally Posted by M J D View Post
    What's the big deal with a drill press? Pilot hole, and final drill. While I have 2 different mag drills, they are often not needed. Kind of like a $1000 dollar solution for a 10$ problem.
    I agree, if he only needs to drill a couple holes.
    I don't have a mag drill personally. Can't justify the cost. But employers I've worked for have. I've also rented a mag drill for a day in the past as well for personal work. I like mag drills for applications like this. No pilot hole required, just a layout and centre punch mark, then drill one hole. Much faster than the drill press for this type of stuff.
    If I had to drill 13/16" holes for 40 or 50 Beveled washers for a critical project/job, I'd be mag drilling them.
    By the way it sounds, I think it would be be most cost/time effective for him to just buy them.


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    Last edited by snoeproe; 01-10-2017 at 01:59 PM.
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    Welding bevel washer

    Don't care for this tapatalk on this ipad
    Last edited by snoeproe; 01-10-2017 at 01:57 PM.
    Jason
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