Welding

Dec 12, 2009

New Honda CB 750 Four Chopper Build !!!! Comming Soon !!!

I recently aquired a Honda CB 750 Four motorcycle, for my son and I to turn into a 21st century chopper. I will be uploading posts at all stages of the build. We plan to fabricate a rigid drag style low seat height frame, rebuilt motor with custom gas tank, forward controls also custom exhaust, and a monster 300 AVON VENOM rear tire. This is going to be a great opportunity to use and show my metalworking skills I have gained during my career. Tig, Mig welding along with english wheel, plannishing hammer and mechanical skills will be neccassary to complete the Honda CB750 chopper project. Stay tuned for all future posts on this and many other projects too come. Thanks again for checking out all my posts on welding and fabricating projects.


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Welding Project Info

Welding Projects, Free Welding Projects, Shop Projects

Drawings

Drawing or sketching is a universal language used to convey all necessary information to the individual who will fabricate or assemble an object.

Prints are also used to illustrate how various equipment is operated, maintained, repaired, or lubricated.

The original drawings for prints are made either by directly drawing or tracing a drawing on a translucent tracing paper or cloth using waterproof (India) ink or a special pencil.

The original drawing is referred to as a tracing or master copy.

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Reproduction Methods. Various methods of reproduction have been developed which will produce prints of different colors from the master copy.

(1) One of the first processes devised to reproduce a tracing produced white lines on a blue background, hence the term "blueprints".

(2) A patented paper identified as "BW" paper produces prints with black lines on a white background.

(3) The ammonia process, or "Ozalids", produces prints with either black, blue, or maroon lines on a white background.

(4) Vandyke paper produces a white line on a dark brown background.

(5) Other reproduction methods are the mimeograph machine, ditto machine, and photostatic process.

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PARTS OF A DRAWING

a. Title Block.

The title block contains the drawing number and all the information required to identify the part or assembly represented.

Approved military prints will include the name and address of the Government Agency or organization preparing the drawing, the scale, the drafting record, authentication, and the date.

b. Revision Block

Each drawing has a revision block which is usually located in the upper right corner. All changes to the drawing are noted in this block. Changes are dated and identified by a number or letter. If a revision block is not used, a revised drawing may be shown by the addition of a letter to the original number.

c. Drawing Number. All drawings are identified by a drawing number. If a print has more than one sheet and each sheet has the same number, this information is included in the number block, indicating the sheet number and the number of sheets in the series.

d. Reference Numbers and Dash Numbers. Reference numbers that appear in the title block refer to other print numbers. When more than one detail is shown on a drawing, dashes and numbers are frequently used. If two parts are to be shown in one detail drawing, both prints will have the same drawing number plus a dash and an individual number such as 7873102-1 and 7873102-2.

e. Scale. The scale of the print is indicated in one of the spaces within the title block. It indicates the size of the drawing as compared with the actual size of the part. Never measure a drawing--use dimensions. The print may have been reduced in size from the original drawing.

f. Bill of Material. A special block or box on the drawing may contain a list of necessary stock to make an assembly. It also indicates the type of stock, size, and specific amount required.

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3-3. CONSTRUCTION LINES a. Full Lines (A, fig. 3-1). Full lines represent the visible edges or outlines of an object.



b. Hidden Lines (A, fig. 3-1). Hidden lines are made of short dashes which represent hidden edges of an object.

c. Center Lines (B, fig. 3-1). Center lines are made with alternating short and long dashes. A line through the center of an object is called a center line.

d. Cutting Plane Lines (B, fig. 3-1). Cutting plane lines are dashed lines, generally of the same width as the full lines, extending through the area being cut. Short solid wing lines at each end of the cutting line project at 90 degrees to that line and end in arrowheads which point in the direction of viewing. Capital letters or numerals are placed just beyond the points of the arrows to designate the section.

e. Dimension Lines (A, fig. 3-1). Dimension lines are fine full lines ending in arrowheads. They are used to indicate the measured distance between two points.

f. Extension Lines (A, fig. 3-1). Extension lines are fine lines from the outside edges or intermediate points of a drawn object. They indicate the limits of dimension lines.

g. Break Lines (C, fig. 3-1). Break lines are used to show a break in a drawing and are used when it is desired to increase the scale of a drawing of uniform cross section while showing the true size by dimension lines. There are two kinds of break lines: short break and long break. Short break lines are usually heavy, wavy, semiparallel lines cutting off the object outline across a uniform section. Long break lines are long dash parallel lines with each long dash in the line connected to the next by a "2" or sharp wave line.

Nov 17, 2009

Welding Table Project


How to Build a Metal Welding Table


A steel welding table is a basic necessity for any welder's workspace, since welding on a wooden surface can present a very real fire hazard. In addition, with a steel table, the welder's work clamp can be attached to it, and parts placed on the table will be electrically connected with the table's surface. This provides the advantage of keeping the work clamp and its cable out of your way while welding. Finally, building your own welding table with allow you to stand upright and place smaller projects at the right height for welding.
Following are instructions for building your own metal welding table. All of the items, with the exception of the metal plates needed for the shelves, can be found readily available at your local home improvement store. The steel plates can be purchased from a local steel supplier easily found in your local yellow pages. Expect to complete this project in less than four hours. The estimated cost for the materials to build this welding table is $50.

SAFETY FIRST

Ventilation
It is important to use enough ventilation to keep the fumes and gases from your breathing zone. For occasional welding in a large room with good cross-ventilation, natural ventilation may be adequate if you keep your head out of the welding fumes. However, be aware that strong drafts directed at the welding arc may blow away the shielding gas and affect the quality of your weld. In planning your workshop ventilation, it is preferable to use ventilation that pulls fume from the work area rather than blows necessary shielding gas away.

Electric Shock
Remember, elecrtric shock can kill. Wear dry, hole-free leather gloves when you weld. Never touch the electrode or work with bare hands when the welder is on. Be sure you are properly insulated from live electrical parts, such as the electrode and the welding table when the work clamp is attached. Be sure you and your work area stay dry; never weld when you or your clothing is wet. Be sure your welding equipment is turned off when not in use. Note that Lincoln wire feed / welders have a relatively low open circuit voltage and include an internal contactor that keeps the welding electrode electrically 'cold' until the gun trigger is pressed. These important safety features reduces your risk of electric shock during any welding project.

Arc Rays
It is essential that your eyes are protected from the welding arc. Infrared radiation has been known to cause retinal burning. Even brief unprotected exposure can cause eye burn known as welder's flash. Normally, welder's flash is temporary, but it can cause extreme discomfort. Prolonged exposure can lead to permanent injury.

Workspace - Protection from Sparks
Before you get started on any welding project, it is important that you make sure your work area is free of trash, sawdust, paint, aerosol cans and any other flammable materials. A minimum five-foot radius around the arc, free of flammable liquids or other materials, is recommended. Extra care should be taken in workshops that are primarily used for woodworking as sawdust can collect inside machines and in other hard to clean spaces. If a spark finds its way into one of these sawdust crannies, the results could be disastrous. If your shop area is too small to allow for a safe radius, please use an alternate area like a garage or driveway.

Gas Cylinders
Cylinders can explode if damaged. Always keep your shielding gas cylinder upright and secured. Never allow the welding electrode to touch the cylinder.

Safety Equipment
It is also imperative to make sure you have all the necessary safety equipment and that you're wearing welding friendly clothes. You should wear:

Welding gloves - dry and in good condition
Safety glasses with side shields
Protective welding shield with a dark lens shade appropriate for the type of welding you do
Head protection - like a fire retardant cotton or leather cap
Long-sleeve cotton shirt
Long cotton pants
Leather work boots
A fire extinguisher should also be on hand during any welding.
Also, make certain no children are in the area when you are welding. They may watch the arc and can experience retinal damage from its intense light. There is also a risk of a child getting burned by welding spatter.

Finally, see the instruction manual for your welder for added safety information. You can also visit the following web pages for added information on safety.

Welding Safety
http://www.lincolnelectric.com/community/safety/
Material Safety Data Sheets
http://www.lincolnelectric.com/products/msds/
Make sure you have the following items on hand before you begin this project:

Required Tools Required Materials
Lincoln Electric Pro-MIG 135TM or other similar MIG welders available at a retailer nears you. The Pro-MIG 135 is powered by 120 volt household current.
Lincoln SuperArc® L-56™ .025-inch solid wire
Gas regulator and hose
Shielding gas with a 75% argon, 25% carbon dioxide mixture
Wire cutters
Tape measure
Square
Speed square
C-clamps (3)
Reciprocating saw with metal-cutting blade or chop saw with metal cutting disc with miter capability
Cleaning solvent - Can be flammable. Keep away from your work area while you weld.
Rust resistant spray paint - Can be flammable. Keep away from your work area while you weld.
1/8" standard steel angle iron (sizes chosen to accommodate 4-foot lengths angle iron is available in):
4-1/8" x 1" x 1" - 18" in length mitered at 45 degrees
4- 1/8" x 1" x 1" - 30" in length mitered at 45 degrees
4-1/8" x 1-1/4" x 1-1/4" - 36-inches in length (legs)
2-1/8" thick mild steel plates measuring 17-1/2" x 29-1/2"
4 - casters with threaded shafts and matching nuts
4 - coupler nuts used to fasten threaded rod together
4 - lock washers to fit caster shafts
1 - steel tubing 3" in length, 1-1/4" inside diameter



Check your materials. Lay out the materials in your work area and check to make sure you have everything required to complete the project. Don't forget your safety equipment and fire extinguisher. If you haven't already, cut your angle iron using your speed square to mark miters. Check the reference chart on the inside of the door of the welder to ensure you are using the right settings for the thickness of steel you are about to weld (standard on most Lincoln Electric compact wire feed welders). Test your settings by welding on a piece of scrap before you start.
Welding the two frames for the table top and shelf. Using the square on the outer edge, place one piece of 30-inch angle iron and one piece of 18-inch angle iron together, mitered side down, making sure they are perfectly square. Attach your work clamp to one of the pieces of metal. With your welding face shield in place, tack weld the corners on the inside edges. The rest of the weld will be completed later.
Using another piece of 30-inch angle iron and another piece of 18-inch angle iron, repeat this step to create the opposite corner of your frame. It is important to weld the opposite corners first to ensure right angles and a perfect fit.

Now bring the two sections of your rectangular frame together and tack weld the remaining corners.






Welding the tabletop to the frame. Position your frame flat side up. Place one of the pieces of steel plating on top of the frame and center it. Attach the work clamp to a piece of scrap steel and lay it on top of the table (see photo). Tack weld around the plate. Do not make full welds at this point to minimize distortion caused by heat. Tack the corners and one or two tacks per side. When all tacks are complete, weld over each tack weld placing a weld with a finished length approximately 3/4-inch long. Finish welding the corners from underneath. Both shelves should be assembled the same way.

Squaring the shelves and attaching the first leg. Stand up one of the shelves on the long edge. Using the square to make sure it is at a 90-degree angle to the ground, attach one of the legs to the shelf with a C-clamp to hold it upright, like a kickstand on a bicycle (See photos). Position the second shelf parallel to the first and attach another one of the legs in the same manner (see photo). The shelves on our welding table are 28-inches apart. You can adjust that distance to accommodate your specific needs. Place one of the legs on the bottom shelf corner and place the top of the leg in the inside corner of the table's top. Tack weld it in place. Next, weld both edges of the leg to the to and shelf. Each of these welds will be approximately 1-inch long. Be sure to weld each side.

Attach the remaining legs. Repeat the instructions on attaching the leg in step 5. Check to make sure you completed all welds on both sides of each leg before standing the table on its own weight.

Attaching the caster coupler nuts and casters. Place a coupler nut in the inside corner of the angle iron, flush to the bottom of the leg. Make a 3/4-inch weld on each side of the nut. Repeat this step on each leg. Let cool. Place a standard nut onto each caster stem as far as it will go. Place one lock washer on each caster stem and thread the stem into the coupler nut attached to the table leg. Adjust the height of the casters to level the table. Then, tighten the nuts to lock the casters vertically in place.


Attach the welding gun holder. With a clamp, attach the 3-inch length of steel tubing to the right front corner of the top shelf of the table (if right-handed; be sure to switch to the left side if you are left-handed). Attach it at approximately a 45-degree angle with the front facing up to accommodate holding the gun (see photo). Tack weld the tube and remove the clamp. Make a 1-inch finish weld on the top side of the tube.

Stand back, admire your handiwork and start on your next welding project. You may want to paint the welding table with a rust-resistant paint, but DO NOT PAINT THE TOP OF THE TABLE. You will want this to remain bare steel so metal parts placed on the table top for welding are in contact with the work. Before painting, clean the entire table with a cleaning solvent to remove machining oils. Mask off the top with masking tape and newspaper. Paint.


If you found this project useful, please bookmark this Web site. In coming months, Lincoln Electric will be adding new welding projects that can be used to enhance your workshop and home.

Jan 9, 2009

Tips for the Hobby Welders

With more and more cable shows showing what can be done with welding, it is becoming more popular as a hobby.

One of the most frequently asked questions I get is what do I need to get a shop started at home? The answer is a BUNCH of money…just kidding, you can actually start out pretty cheap. But one thing you gotta' remember is cheap is not always good when it comes to tools and welding equipment.

It used to be hard to find a place that sold welding equipment other than a welding supply store, but that has changed drastically over the last few years. Now there are paper catalogues, on-line catalogues, local hardware stores and big chain hardware stores such as Home Depot,and Loews. I remember the welding equipment section at Home Depot and Loews barely taking any space on a shelf, and now they have their own section not only with welding equipment, but also machines.

Northern Tool and Harbor Freight come to mind for paper or on-line catalogues, and actual stores where you can obtain welding equipment. Most all of these have both top-of-the-line products, and cheaper not-so-top-of-the-line products. I bought a few grinding brushes for my shop the other day at a fraction of the cost I usually pay. And they lasted a fraction of the time also!

I know better than to buy welding equipment that is way too cheap, or know nothing about, but I got suckered in by the low price. I "figured" a brush is a brush, but boy did I figure wrong. That's not to say there aren't some good deals out there. A lot of times stores will be over stocked in welding equipment and just like any product want to get it off their shelves. That's when you can find the real bargains if you keep on the lookout.

The more you check out the catalogues, and visit the stores, the more you'll get an idea of the costs of all the welding equipment out there. You'll also start becoming more familiar with all the different kinds of tools available, many that are very handy, and a lot that you can do without.

I once had a friend walk into my shop looking like something from outer space. The welding supply store had sold him about $250 bucks worth of stuff he didn't need. I sent him back for a refund for everything but his gloves, hood, chipping hammer and brush! You can check out craigslist, ebay and Harbor freight for deals on tools and equipment.

Jan 7, 2009

Jay Leno Promotes Welding

I came across this video at youtube and thought it would make a good video for my next post. Jay's right, we are in need of lots of young people to follow in the welding and fabrication industry. I'm a second generation sheet metal fabricator / welder and have been doing it for the past 28 years. The average age of workers in these positions in my area are mid 40's. Hope there are still young men and women that want to work with thier hands and join these industries.

Jan 1, 2009

Rent Smartflix How To DVD'S

I recently found a online business that rents it's DVD's much like Netflix but this company only rents instructional DVD's. The company is SMARTFLIX, check out there catalog here SmartFlix.com How-To DVDs. I think this is a great way to get great instructional videos without having to buy them. Check it out I will be posting my reviews as I have them. Thanks for now, come back and check us later for more projects / info.

Tig Welding Basics DVD


TIG welding has been long recognized as the premiere welding process, which can make beautiful, strong welds on nearly any metal. In this easy-to-follow program, Ron Covell covers the basic processes used for TIG welding, covering proper machine setup, joint preparation, electrode selection and preparation, torch technique, and perhaps most importantly, what to check for when things go wrong! Ron’s thoughtful description of the welding process, coupled with the close-up photography that brings the action into clear view makes the seemingly difficult process of TIG welding easy to understand. You can now rent the DVD at Smartflix here TIG Welding Basics

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