Welding Tips and Tricks

After messing around making an X-Y-Z template for pipe corner joints I decided to make another of Jody's "open concept" carts but using 1-1/4" sched 40 pipe instead as I had a length of used pipe on the rack I couldn't use on the job and I also had wheels, castors and 3/4" short radius elbows lying around looking for a use, so here it is.
Cut all the materials and coped all the pipe ends, it turned out to be easy to clock them all accurately. All I did was chalk a straight line down the side of the piece and used it as the start point for the cope wrap.
All copes were cut with a worn wafer blade on a 5" angle grinder. I tried other methods like band saw and plasma, much cussing, the angle grinder was fastest and most accurate cut. Cleaned up with die grinder and no cussing.
Tacked up the two sides then tacked in spacer pipes
Had perfect fitups but I offset every joint as I knew what was going to happen from experience. It did happen and pulled into perfect square and alignment - yes!
Welds are not too shabby
Thumbs up for Mag-Tabs
Used a piece of 40mm square tube for the cylinder stand. Gonna put aluminium tread plate on it to protect paint work.
Made up the castor caster mounts and instead of welding on the casters, this time I drilled and tapped holes in one go with these great bit/tapper bits. This one is 6mm (about 1/4"). Fitted up all the wheels nice and level 2" castors and 8" wheels all with bearings.
Final fit up with 3/4" pipe handles and cable hooks just like last time.
I used 2" x 1/8" (50x3mm) flat bar on edge to frame the shelves. Aluminium tread plate will be riveted on when finished.
Made provision for two cylinders on the cart this time.
All painted up and of course me being a one eyed Miller guy, it's gotta be blue!!!

All that's left is the tread plate shelves and retainer chains for the cylinders. I didn't want to buy a whole sheet of tread plate cos I don't have a use for the rest of it so I'm gonna wait for a score. I'll post a pic when its done, might be a while.

nice design looks great!
craig

Wow! Nice job! Nice touch using the galvie caps on the cable hooks...or are those stash tubes

Nice job! Iv'e never seen those drill/ tap bits, very cool..

Hey Exy, they are pure unadulterated cable hooks.

@pgk
The drill/tap bits are very cool. I think the eight tapped holes took less than two minutes after centre punching . With trefolex it seems to glide through like butter.


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Coldman wrote:Hey Exy, they are pure unadulterated cable hooks.

@pgk
The drill/tap bits are very cool. I think the eight tapped holes took less than two minutes after centre punching . With trefolex it seems to glide through like butter.


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Very nice!

pgk wrote: Iv'e never seen those drill/ tap bits, very cool..

x2, never saw them before. But i'll have to find some now!

i love new innovate tooling, i don't know how i missed these
bits! who makes them?
craig

I'll take a pic of the label shortly


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All the labels are worn off.

Here is the link to the manufacturers web site:
http://www.pretooling.com.au/products/c ... -taps.html

Looks like an Ozzie company, how bout that.

If you look at their little demo tube they used an electric pistol drill and operated the bit dry.
It works fine dry, I used a battery drill and could feel the dry friction. Added trefolex the next hole and no resistance, just glided through. I have the full set from 3mm - 10mm for a few years now and have not broken a single tap yet. Thickness of plate you can tap is limited by the length of drill extension that must penetrate right through before the threads engage but in every case this length is much more than the hole diameter. They claim up to twice as much but I haven't measured. That means the 10mm bit can be used on 20mm plate. Impressive.

If I buy a set of them I won't have to keep the right size bit taped to the correct tap.

OK here is an American equivalent site
http://www.natool.com/products/special- ... -drill-tap

That's a nice assortment of parts you all have laying around. Must have a nice scrap and part pile around your place. At least parts that I would like to have.

Now you've gone and alerted the sticky beaks.
One day I'm gonna do a tidy up. Always seem to be too busy.


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Nice work as always Coldie.


K

Well done mate !!!

Thanks fellas. Hi mossie, haven't heard from you for a while, welcome back.


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So I eventually scored some chequer plate drops and here is the finished beast.

I like that plate!

Sweet! I'd certainly use checker plate if I had it. I think Jody has said, "There's no kill like overkill," and the guys on Mythbusters like to say, "Anything worth doing is worth overdoing."

Words for a welder to live by.

Steve

I just noticed the sign on the door. That's classic! I sneeky peeked anyway...

Otto Nobedder wrote:Sweet! I'd certainly use checker plate if I had it. I think Jody has said, "There's no kill like overkill," and the guys on Mythbusters like to say, "Anything worth doing is worth overdoing."

Words for a welder to live by.

Steve

I'm building a trailed hitch for my shop teachers dock section to pull in and out of the water out of angl iron and some tubing. 3-pass fillet on the tubing and 1/4" gussets for a 250 lb dock section at the most. I figure you can't have too much strength in a weld joint on something like this.

Ah yes, something for everyone in my posts.

Ps it took a while to hook you, first pick was more subtle so this time I was more obvious.


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Coldman wrote:Thanks fellas. Hi mossie, haven't heard from you for a while, welcome back.


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Cheers Coldie.

Yeah, life took an interesting turn for a moment there so I was off the air for awhile. Nothing too dramatic and all back on track now. Very happy to be loitering around these parts again.


Moz

Coldman wrote:Ah yes, something for everyone in my posts.

Ps it took a while to hook you, first pick was more subtle so this time I was more obvious.


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I was admiring your awesome cart when I saw some boobies out of the corner of my eye. Well played sir!