Welding

Nov 18, 2008

Stick Welding Hints & Tips

Always read and follow the safety precautions and operational instructions in your owner's manual.

1. Take precautions with flying materials when chipping slag.
2. Keep electrodes clean and dry - follow manufacturer's recommendations.
3. Common steel electrodes: (Refer to Diagram 8. Recommended Stick Electrodes)
4. Penetration: DCEN - Least penetration, AC - medium (can be more spatter also), DCEP - most penetration.
5. When welding a fillet, the leg of the weld should be equal to the thickness of the parts welded. (Refer to Diagram 10. Recommended Fillet Weld Thickness)


6. To set your amperage control, first determine recommended amp range for your electrode type and diameter. Then pick an amperage within the range based on your metal thickness (thinner metal, less amps). (Refer to Diagram 7. Example of Good and Bad Stick Welds)








Scratch Start TechniqueDrag electrode across workpiece like striking a match; lift electrode slightly after touching work. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free it.1. Electrode2. Workpiece3. Arc
Tapping TechniqueBring electrode straight down to workpiece; then lift slightly to start arc. If arc goes out, electrode was lifted too high. If electrode sticks to workpiece, use a quick twist to free the electrode.1. Electrode2. Workpiece3. Arc


Nov 16, 2008

Texas State and Longhorn Receiver Hitch Cover


A friend of mine Johnny is a very artistic and skilled welder fabricator. I recently visited him at his shop in Austin, where he creates custom items using Texas icons in the designs of his projects. During my visit he showed me his latest creation of a custom receiver hitch cover. The cover is made of 100% stainless steel and fits all 2" receivers, it was created using a plasma cut Texas Longhorn, Texas shape, Oval Ring and Stainless wire rope edging. This is one fine item and the pic's I posted below doesn't do it justice, to the fine quality and detail he used in the creation. He will be selling a few of them and I will have a link below to purchase with pay pal. The hitch cover is 3 dimensional longhorn stands 1/8 inch in front of Texas shape then they are attached to the oval ring using his tig welder. The Longhorn shape is a matte finish, all other pieces are polished to mirror finish. He makes the stainless steel rope trim himself and makes the design pop out. Just wanted to promote projects created by other native Texans. If you purchase one of these limited quantity hitch covers you can feel good that your funds are going to a USA Lone star State American product with no imported items used. Please feel free to contact me with any questions.







Aug 27, 2008

Texas Longhorns Portable BBQ Pit

Here's a completed project a friend of mine finished. It's a reciever hitch mounted BBQ Pit. Made of all Stainless Steel and features a Texas Longhorn formed from flat sheet metal. It was placed at top of stack. Also it has Texas shapes cutout on the side for baffling. It sits on a hitch mount that swings away for access to you rear door or tailgate. I've included pics below. This project was built using the tig welding process, along with alot of polishing of the stainless. Detailed plans are available please contact me at texramsey@gmail.com


Aug 23, 2008

Need a New Career? How to Become a Welder

Anyone looking for a blue-collar career using their hands might be interested in learning more about welding. Many apprenticeship programs will accept candidates who have completed tenth grade or higher at the high school level, although a high school diploma or GED is preferred. The most important physical skill is manual dexterity, physical health, and ability, along with analytical skills and technological savvy needed for operating a computer. So if this description doesn't fit you, it might be better to consider another occupation.

Key welding skills expected of those who complete advanced skills training include the ability to weld a variety of alloys in many kinds of positions. Additional skills include those who can weld ferrous and non-ferrous materials on pipe and on plate. Many programs build within a three-tier system of training that begins with basics and moves on to specialized welding capabilities for a variety of worksite situations. Ongoing training may be expected, depending on the employer's need and job market conditions.

Those who want to become welders often begin by enrolling in an educational program. These programs featuring welding certificates are offered at many community colleges or regional campuses of state or private universities. The academic program provides preparation for welding by explaining theories and applications before putting equipment in the hands of beginners. To apply, you may need to provide your high school transcripts, a driver's license for identification, and possibly a birth certificate. Each institution's requirements may differ, so find out in advance what type of documentation you will need to bring with you to enroll. Upon completion of the program, you will receive a diploma or other type of skills certification document. Hold on to this, as you may need to show it to your employer later. Many companies frame and mount their employees' certifications and subsequent awards.

After successfully completing a program of instruction, you will be able to look for a company that sponsors an apprenticeship program. If you get hired, you can work with professional welders to learn how to actually perform welding jobs, working with many kinds of projects, materials, and positions. You may need to work a certain amount of time, like so many months, in order to complete your training and become a certified welder (CW). When you earn your credentials, you may choose to stay with your present company or search for employment with other firms.

As your skills increase, so will your pay and the opportunity for full-time employment. Some companies will pay for welders to participate in training seminars or workshops in town or out of state. These can take anywhere from part of a day to a week or longer, and the company usually pays all the expenses for an employee to attend, including registration, motel, and travel costs. As you earn more certifications, you will become even more employable, which can lead to increased pay and benefits in the future.

If you are looking for an exciting career with potential to grow, consider welding for your long-term job choice.
Check out these books and videos to get you going !!!

Aug 15, 2008

Formula for Rolling Sheet Metal Rings

Today, I had to fabricate some .188 thickness stainless steel parts. Two of the items had to be rolled into rings. I would like to explain how to determine the proper length of material to be used when rolling metal into rings. You start with the overall diameter of the ring. For example lets use 24" outside diameter. Material is .188 thickness.
Take .188 x .6 (60% of the metal thickness)= .1128. Take .1128 x 2 = .2256. Then the diameter 24" - .2256 = 23.774 flat length to make a 24" O.D. Ring. Hope this is a help for any projects you may have that require a ring to be rolled.

Aug 8, 2008

Beginners How to Arc / Stick Weld

Learning how to weld is not as hard as you might think.
All you have to do is simply follow a few basic steps, to get that welding down pat. It's like baking a cake or building a house. You need to follow a set way of doing things.
There are a few basic and easy to learn steps that you need to take into consideration before you even attempt how to stick weld or arc weld.
A lot of the time, people simply just rush in "guns blazing" and when they have a go at it half a dozen times and they can't do it, they give up. Listen, like I've said, stick welding might seem a bit daunting at first. But once you learn these basic steps on how to arc / stick weld the whole process will become a lot clearer to you.
How do I know? I've been there and done that. I know how hard it can be to learn how to stick weld for a person who has never welded before in their life. Often the first timer will make a few silly mistakes that can spoil their first time stick or arc welding experience.
Things like:
• How to strike an arc and keep it going. This is a big issue for anyone who is learning how to stick weld. How do I do it? Why does it keep sticking to the job?
• What size welding electrode should I use?
• What type of welding electrode should I use?
• What about welding safety. What should I be aware of when welding? What will hurt me and put me at risk of injury? If you are new to welding, you might not be aware of what to look out for.
• Which way do I move the electrode?
• What power setting should I set my machine at?
All these and many more questions are what the DIY'er or learner welder need to find out.You need to.
1. Learn how to stick weld and arc weld the right way the first time.
2. By following a set of easy to understand step by step instructions.
Which means...
3. By having a successful first time arc welding experience, you will never have a negative experience, therefore your ability to learn will not be ruined by a bad first time experience. Check out these books and videos to get you going !!!



Aug 3, 2008

How to: CNC Machine Tool Cart Build

Last year a friend of mine contacted me to build 2 Tool Carts for his precision machine shop. The carts were to hold the CAT 40 tooling for his 4 HAAS CNC Vertical Milling machines. I found through research that a company named HUOT made a cart for this same application. I fashioned my design very similar to theirs, but my final product is less expensive. I started with 16 ga crs material for the carts. I also found heavy 5" iron/rubber casters with 330lbs rating per caster from Harbor Freight. The handle I made from .125 thk 5052-H32 Aluminum. These carts are very stout and will handle all the tools he needs for the machines. The carts are made from 7 different sheet metal components, top, middle, bottom, sides, end trays, and tray brackets. I assembled them using 1/4-20 thread cadium plated bolts with locking nuts. It took a weekend to get them built and assembled, and another day for paint. I had to install plastic bushings in the tool holes to keep the cart from scratching the tools when holding them. Check out the pics of the carts ( my son helped me out ). Thanks for comming to my blog. See ya.


















Jul 26, 2008

BBQ Pit Fire Box Build




Recently, I was contracted to build and install a custom fire box for a BBQ pit. The pit was made from a piece of 22" pipe with 3/8" wall thickness. I fabricated the box using 1/4" HRS (Hot Rolled Steel). The measurements are 18" x 18" x 22" and had a full size swinging door on end with sliding damper. I used a Hypertherm Powermax 1000 plasma cutter to cut all pieces to size. I used my Hobart Handler 130 mig welder to tack all box pieces together and then final welded everything using a Lincoln AC/DC Arc welder using 6011 rods (nothing like smelling burning rods in the morning). Everything came together very nice in one weekend, and customer was very impressed. Turns out it was a bbq pit that he inherited from his grandfather. I was glad to do the work, and gained some more leaning experience while doing so (I want to keep on leaning). So long for now, Doug Ramsey























Feb 5, 2008

Aluminum Water Feature Basin Tank













Recently I was contacted by a fellow Dripping Springs resident about the fabrication of a tank for his stone and tile water feature built in his coutyard. I fabricated it from .125 thick 5052-H32 aluminum. The dimensions were aprox 12" high x 14" width x 48" long having a capacity of aprox 14.5 gals of water. It was a very straight forward project that required the use of a Power Shear, Hydraulic CNC Press Brake, and a Miller Syncrowave 250 for the tig welding GTAW, we had to do to create a water tight seal. See pics of this project. I will be adding completed Tank installed at a later date.

More of the Chevy BowTie Exhaust tips project



This project is progressing as planned. Johnny has added a 1" width band of 16ga stainless steel to the end of tip. It has been welded complete on end now and the 1st polishing operation has been done, see photos. I will update as project moves forward.

Jan 29, 2008

New Project: Bowtie Shape Exhaust Tips



















Johnny and I have recently started a project to fabricate a set of Stainless Steel ehaust tips in the chevy bowtie shape. This will be ongoing for the next week or so. Come back to see the completed set, they're awesome. 1st Johnny gave me a layout of the exact shape. I then layed out the pattern making each bowtie in 2 seperate mirror image pieces. I sheared them and then deburred all edges and formed them afterwards in the shape you see above. The material is #4 Stainless .160 thk. ( made from 1 piece .104 thk. and 1 piece of .06 thk.) The pics above show the progression of the build. Stay tuned and come back for the next step of this project. As always please email if you want more detailed info. Thanks for now,Doug & Johnny.










Jan 23, 2008

Useful Welding Book

I would like to share a book with you that has been of great help with all my projects. The book Performance Welding by Richard Finch, is full of great information about welding. It covers :
* Mig, Tig, Arc and Oxyacetylene Processes.
* Shopping for Welding Equipment.
* Fitting and Cleaning Metal.
* Jigging.
* Tig Welding Steel and Stainless Steel.
* Tig Welding Aluminum and Magnesium.
* Mig Welding Steel and Stainless Steel.
* Mig Welding Aluminum and Magnesium.
* Gas Welding Steel and Stainless Steel.
* Gas Welding Aluminum.
* Welding Shop Safety.
* Welding Supplies.
* Sources for Metals.
* Shop Math.
* Glossary of Welding Terms.

You can order this book by for under $20 bucks by clicking here: Link to Amazon

Jan 21, 2008

Texas Star Piggy Bank




A friend of mine just finished building a Texas Star Piggy Bank, for his son. The project was built using #8 Mirror Stainless Steel material. Material should be available from your local supplier or you can order online at http://www.onlinemetals.com/. After cutting out the (2) Star shapes, he cut (5) pieces in a rectangle shape, then formed across the middle in the direction he wanted. This makes the pieces that create the depth of the piggy bank. After all cutting and forming was done he tig welded all edges for a seamless look. After all welding then came the grinding to blend welds and then polishing to match the #8 stainless material. Above is a picture of final product. If you would like the detailed plans please email me texramsey@gmail.com

Jan 19, 2008

Welding Table Project

I found a great welding table project for anyone who needs a good welding table at home or business. Click here for details:http://www.millerwelds.com/interests/projects/welding-table/

Used Welding Equipment

I have found some great welding equipment such as Welders,Shears,Brakes,Punches that I use in my shop at http://www.hgrindustrialsurplus.com/. I will be listing a new project every week with written instructions as well as some videos. If someone has some projects they would like to contribute please contact me.

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