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Re: square peg round hole Originally Posted by vdotmatrix Yes those are the dimensions. I hate to rush right into any welding project unless i am sure about things. I tacked everything up because it took so long to line it up and i didnt want anything falling over on anything or anyone. I am going to hunt down jody’s video.....I appreciate your interest and the time... thank you. Weld it and be done with it...if you wanna put a small piece of rod in the gap to make life easier do that...we do this stuff evry day on bigger heavier stuff than this and it takes a lot more abuse than this thing will ever see. Bounce around after you tack it good to keep it from pulling out of position. Get after it and move on to the next part of the job or you will never get the thing done
Re: square peg round hole
Re: square peg round hole Yes those are the dimensions. I hate to rush right into any welding project unless i am sure about things. I tacked everything up because it took so long to line it up and i didnt want anything falling over on anything or anyone. I am going to hunt down jody’s video.....I appreciate your interest and the time... thank you.
Re: square peg round hole Originally Posted by shovelon From what I see the arc is going to want to follow the path of least resistance. That would be the thin wall of the small tube. So that wall is going to want to go bye-bye if left open. Anything to close up the gap will take heat off the thin tube while building heat in the thick tube. I have grown partial to pulse settings for heat management.....
Re: square peg round hole What sizes, and thickness of tubing are these ? 2"sq x 1/4" wall to 1-1/2"sq x 1/8" wall ? Make a few test pieces, and have at it . Hood time is how you're going to figure it out. This job has a lot of metal, so it will be forgiving of any method you use. I've done lots of machine frames, and guards using 7014 on AC and DC, and the come out really smooth. If you get the angle and amperage right it will look like a mig weld. When I have a dozen or more of these welds to make, Gas shielded flux core works really well, and isn't to smoky compared to gasless, or even MIG. 7018 would be a good choice too, what ever your comfortable with. If your going to TIG this and you're nervous, look at the video Jodie made when he constructs a Test bending rig. He uses a Lincoln 210mp to weld some 1-1/2" cold steel rounds together without coping them. He has some good pointers that might make you fell more confident , if you haven't already started. HTH Best of luck
Re: square peg round hole Originally Posted by vdotmatrix When welding on materials of different thicknesses, what is the rule of thumb? Weld for thinnest material? If using a setup guide, I go half way in between and concentrate heat on the thicker piece and let the puddle flow to the thinner one.
Re: square peg round hole When welding on materials of different thicknesses, what is the rule of thumb? Weld for thinnest material?
Re: square peg round hole Originally Posted by villageblacksmith There are multiple ways of getting this welded, and I am neither discounting nor advocating the advice given. I just would like to mention how little grinding of the thinner tubing would actually be needed to achieve a LOT better fitup. I thought of this but sculpting the thin tube in such a precise way to end up with that tube perpendicular to the thick walled would be tricky.
Re: square peg round hole Originally Posted by Welder Dave I think some are over thinking this. Unless it's a real critical weld just tack a piece of rod in the gap and weld it up. That's what you'd do in a shop if you had a gap. That’s what I am about to do. 1/8” rod will fit nicely...
Re: square peg round hole Originally Posted by Welder Dave I think some are over thinking this. Unless it's a real critical weld just tack a piece of rod in the gap and weld it up. That's what you'd do in a shop if you had a gap. From what I see the arc is going to want to follow the path of least resistance. That would be the thin wall of the small tube. So that wall is going to want to go bye-bye if left open. Anything to close up the gap will take heat off the thin tube while building heat in the thick tube.
Re: square peg round hole There are multiple ways of getting this welded, and I am neither discounting nor advocating the advice given. I just would like to mention how little grinding of the thinner tubing would actually be needed to achieve a LOT better fitup.
Re: square peg round hole I think some are over thinking this. Unless it's a real critical weld just tack a piece of rod in the gap and weld it up. That's what you'd do in a shop if you had a gap.
Re: square peg round hole How about welding a square piece of flat bar, maybe 3/16" thick, to the top of the horizontal tube, and then welding the vertical tube to that? Then you'd have a nice flush fit for the thinner tubing.
Re: square peg round hole I sometimes tack a small insert into the thin tube to help keep the walls from melting back. Those joints can be challenging.
Re: square peg round hole Always the same with box section joints, but it's worse with heavier wall stuff. Tack it well, weld the fillets first and then fill the gaps... all 3 welding processes will do this no problem.
Re: square peg round hole Originally Posted by Kelvin Tack it good (in the middle of the joints) so it won't pull out of square due to weld shrinkage, then weld it up. Next question? I am anxious to roll out of bed and get started. I was all ready yesterday until I found the gaps during fit up, the bottom of the thick wall has a slightly narrower straight section. Thank you for taking the time!
Re: square peg round hole Stick is inherently thicker than TIG. I did some stick at my father in law’s but Of the three , mig, tig and stick, i have the very least experience with stick; and my least favorite process. I have a few sticks of 7018, and i have no concerns of blowing a hole in the thick wall stuff....the vertical tube is much thinner, i think between 5 and 7 /64ths, , hate compounding the headache by having to go back and fix my fixes......thank you for responding
Re: square peg round hole Tack it good (in the middle of the joints) so it won't pull out of square due to weld shrinkage, then weld it up. Next question?
Re: square peg round hole I like to tig these with 1/16" wire in one pass. Fills it in up to flush. No grinding and if you lay a nice bead it's perty too.
Re: square peg round hole Very often, if the tubing has a large radius, you can fill the gap in two passes. I usually wind up having to do it quite a bit because 7018 doesn't like the necessary whipping to fill large gaps. Attachment 1719896 Put a bead in there to start the gap fill process Attachment 1719897 Then grind it back in order to have a uniform base for the finish pass. You have a nice base, and you don't have a lumpy filler pass. Attachment 1719898 Now you can lay the final pass in,, and it looks pretty decent if you take the time to do it right. Attachment 1719899
Re: square peg round hole Originally Posted by Welder Dave You could always run a bead on the thicker tube to fill up most of the gap and then run a 2nd pass to fill it. If it's not critical at all, lay a piece of round bar in the gap. In a shop you'd lay a 1/4" or 3/16" rod with the flux knocked off to fill a bigger gap. yeah, that would be so much easier. 3/16” round stock, fit it in and weld it down. Awsome....
Re: square peg round hole Originally Posted by tapwelder That's better. Looks like the large radius on the heavy wall leaves a space between the butted thin wall tubing. And looks like the thick wall tubing is about .25 inch wider than the thin stuff. If critical and it has to be closed up, then I would shape thin tubing to mate with the heavy tubing. Though if not critical, I would weld it up as is. Thank you for responding. Here is the other end. It will fit into the receiver of my hitch, thus the hole i drilled. The magnet at the 90 degree there is where a gusset I made will be welded. I may just weld the the surfaces that fit and then the gusset. I can always cut a scrap strip and pulse it in to fill in that gap and then grind smooth. Attachment 1719884
Re: square peg round hole You could always run a bead on the thicker tube to fill up most of the gap and then run a 2nd pass to fill it. If it's not critical at all, lay a piece of round bar in the gap. In a shop you'd lay a 1/4" or 3/16" rod with the flux knocked off to fill a bigger gap.
Re: square peg round hole That's better. Looks like the large radius on the heavy wall leaves a space between the butted thin wall tubing. And looks like the thick wall tubing is about .25 inch wider than the thin stuff. If critical and it has to be closed up, then I would shape thin tubing to mate with the heavy tubing. Though if not critical, I would weld it up as is.
Re: square peg round hole Originally Posted by Welder Dave Actually the fit up with the rounded corners is pretty much the best fit up you could have. Makes for full penetration for maximum strength. I need to post a better picture from the side(s). Attachment 1719880 Attachment 1719881 Attachment 1719882 This is what I have to work with. (Sorry about how the images display).
Re: square peg round hole Just fill with welder Some time a large hammer work for holes This is not wood work It is steel weld or hammer sometime both Dave Originally Posted by vdotmatrix Attachment 1719860 This displays upside down...how aggravating. But you get the idea. Attachment 1719861 I am still working on my T-bar canoe support and just have to weld this and can prime and paint. NOT SO FAST. As you can see, there is alway a complication i can weld the tube in place and build the sides up to fill the nightmare gaps. I could grind a flat spot on the base, ugggg. or I could notch out the tube to fit the base. ugggg or, I could cut off a precise slice of tubing to fit either side. ALWAYS SOMETHING..any ideas? i have to get to a computer to post rhe two pictures, cannot do it from iphone
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