How would you weld this?

[bittiker]

I'm about to weld about a 100+ 3/8" SS rods to 1/4" SS plates as shown in the attached image.



How would you go about it?

1. What would be the best equipment to use?
2. What's the best weld type for this application?
3. Any general advice would be really appreciated. I'm going to be welding so many of these that I wan't to make sure I'm doing it right.

Thanks, Danny

[DSW]

All stainless? I'd be tempted to drill the plates, insert the rods and tig them in from behind rather than the way they did them in that pict.


Small round stock like shown in the picts is a PITA to weld either with mig or tig. It's tough to get the gun or torch around fast enough with something that small. If you weld from the back, then you have a flat surface and can simply weld then in no problem.

[VPT]

What are they used for? What kind of pressures/weight/forces are put on them? What machines do you have access to?

[bittiker]

I'm going to use them as table legs. They'll need to withstand about 500lbs of weight.

I'm going to buy new equipment for this job, any recommendations would be helpful.

[TimmyTIG]

stainless stick

[zapster]

I'm going to buy new equipment for this job, any recommendations would be helpful.

I would tig it..be done in no time..


I don't like this one bit...
Do you have any idea what you just ate?

Here we go.

...zap!

[SquirmyPug]

I would tig them. I did 750 of these, 100 won't take long. Sorry the pics are all sideways

[bittiker]

I'm an amateur welder at best. I'm trying to go with the most fool-proof method. If I drilled a hole, and welded from the back, would I drill a slightly bigger hole? Or use the same dia. drill bit?

Also, if I were to weld from the back, could I use this MIG welder? Or would I need something more heavy duty?

http://www.amazon.com/Pro-Series-MMI...1&keywords=kit

[DSW]

I'd go with the same size hole myself.

That welder isn't really the right tool for stainless if you want it to stay stainless. For that you will want a mig that uses gas vs a small flux core welder. Understand to mig stainless it will not be cheap. Stainless mig usually uses a trimix gas specifically for stainless. My supplier doesn't usually stock small cylinders of this gas, but can order then is as needed. It is not cheap.

[walker]

Ditto DSW, I'd punch them out on the ironworker and tig from the back. Update your user cp with your location and you might find somebody willing to help you out.
100 of them isn't a lot, maybe a days work.

[Mr. Moose]

You'd do way better with the punch and weld from the back method. The welding from the back method is just a flat weld, and you'll be able to do 5 of them in the time it would take to do 1 of the flllet weld around a very small rod method shown in the pics, plus if you're not experienced in doing the small circumference of the fillet weld method, you'll have a substantial learning curve before you get to production....

SquirmyPig, what is that thing used for?

[Boostinjdm]

Are they for a restaurant or something? All on one table? Or 25 tables? For your use? Or did you accept a job you weren't ready for?

[tapwelder]

Mr. Moose, Duh, It's a dime holder.

Bittiker

Learn to weld first, Seems like a serious project 500 lbs capacity. Not a lot a weld to hide your lack of ability. Might want to pay somebody to do it.

Good luck

[Scott Young]

drilling stainless is a chore if you have never done that before. I would second the punch, but many shops will charge more for punching stainless than for punching mild steel. Lastly, I am not sure he knows how to tig. Stick welding from the back would be cheaper in the long run due to needing just a cracker box. if he already had a cracker box and wanted to add a tig stinger to it then he is looking at another 200-300 dollars. on the cheap.

[Scott Young]

That looks like the same high dollar gig set I use from time to time.

[weldermick]

Here's another vote for punching the holes and welding from the back.

• Don't attempt to drill the holes yourself, you'll regret it - just outsource.
• Make sure you have a jig set up so that everything slots into place nicely at the required angles/heights.
• Have it so that the rod is recessed slightly from the back of the plate, so the weld bead doesn't protrude above the face of the plate (assuming you want to keep it flat).
• I'd reach straight for a tig machine - you'll get a quick neat weld with no cleanup required.
• When you get the holes punched, they'll probably come back with oil and crap on them, so you'd be best advised to dunk them all in a cleaning solution and a wipe down with acetone before welding.

[SquirmyPug]

Mr.Moose, the name is SquirmyPug and the part is an adjustment handle for a tool called a Knucklemate..something I don't think anyone here has used .

Scott Young..it is high dollar it has made us alot of $$

[forhire]

Can you buy them for less than making them?
http://hairpinlegs.com/products.php?id=1

If you decided to have the holes punched or drilled remember that the legs are cambered a few degrees. I'd lay out my fixture and then experiment with the hole size as you likely need to oversize a little. In an ideal world you'd drill the holes at the appropriate angles for the camber but angled holes cost more than flat drilled or punched.

Do the exposed welds have an aesthetics value?

[Donoharm]

stainless stick

Stick would be the fastest and way cheaper then any other process.

SS stick can be as nice as tig , you have 100 tries

You have about 6-8 hours hard work (including cleaning) \I would finish faster, go home drink some beer

Happy new year guys !!!

[Blackhawk]

knucklemate,,, appears to be for loco/ car knuckles.. hmm, learn something new every day .

[jdbuckshot]

drill the hole

insert the rod half way throught he plate, leave it about 1/8" from flush on the back side, and weld it up with the mig.

it the wel is beyond flush grinder down!

[Fred s]

Those plates in the sample don't look 1/4 to me, if the rods are 3/8

[TimmyTIG]

you're building a 500 pound table with those little rods for legs?

[jtcnj]

I apologize if I'm wrong, but is this spam?

The OP wants to weld up something to withstand 500lb, stresses, seems to have no idea of the equipment or processes or difficulty involved and asks if a 110V flux core machine is up to the task.

I'm just wondering ......

If not: I like the punching or option and weld from the back, but would it be reasonable with limited equipment options I am assuming the OP has available to tig the fillet and stop a couple times to turn the piece, since it is difficult to manipulate around the small diameter without a turntable positioner? How about some simple positioner kinda like the old sit n spin kids toy you could spin with your foot?

[SquirmyPug]

I apologize if I'm wrong, but is this spam?

The OP wants to weld up something to withstand 500lb, stresses, seems to have no idea of the equipment or processes or difficulty involved and asks if a 110V flux core machine is up to the task.

I'm just wondering ......

I didn't notice that he said they are table legs, but I see now. Maybe it is spam..Don't know