Tig welding tips, questions, equipment, applications, instructions, techniques, tig welding machines, troubleshooting tig welding process
jcw
  • jcw
  • Workhorse
    Workhorse
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Thanks! Cool project you are doing!

I've filled tubes with sand and bent them with an oxy/acetylene torch over a wooden buck before. Not pretty or elegant.
Keith_J
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    Tue Dec 20, 2016 1:55 am
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Just had a real eureka moment. The tubes are magnetic from final draw. I've made a tube furnace to normalize the material. Not only removes strong residual magnetism but makes bending easier.
Keith_J
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Ever have an "oh CRAP" moment? Yep, scratched cornea. All better now. Bends and copes done, just down to fitting, tacking and welding. Great news is new hole saws at correct speed do a wonderful job at cope miters in the drill press with Harbor Freight tube notcher. 1600 RPM on a 1" Milwaukee bimetallic is golden. Blue chips are the goal so watch feed. No cleanup other than debur.

Have to say Blue Ox Lenox hole saws seem to cut better but are more fragile. But WTH do I know as this is my first CrMo rodeo. I do know when feed and speed are right, it cuts great and fast.
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When chips turn blue, all is good. Put heat in swarf and the tool will stay cool.
Last edited by Keith_J on Tue Mar 28, 2017 2:13 am, edited 1 time in total.
Keith_J
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Another view of that 1" OD 0.120" wall 4130..
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Three tubes intersect here and this is a tube gusset .
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Keith_J
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Almost done. Need to remove a slight warp and then complete the rear triangle. Too much work even with every weekend a three day (work 4-10s on W2 ).

Will post pictures once capable.
Keith_J
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Chedda!
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Yes, that is a Ryobi grinder. I bought it because HD wouldn't cut 20 foot rebar and I had a charged One battery in the truck. One less cord on the bench.
Keith_J
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    Tue Dec 20, 2016 1:55 am
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We have a bicycle!!
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Only have one front axle as these purchased parts are 416 stainless and required a redesign as I won't weld such a part due to stress and material. Sure, it could be done but the part is designed and purchased so use it as intended. I did one steering knuckle and it worked so the team will use the university machine shop to replicate.

I also fabricated the knuckles from A36 1/4" plate. Fun welds for a change.

The hardest was the rear triangle. Laid it out, jigged the dropouts and tacked it up. After welding, the wheel dropped in with NO cold setting of the spacing. 135mm on the money.
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