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View Full Version : Making progress with more test welds, made a 10 gauge extensin cord, easy!



tomas
01-13-2009, 12:08 AM
See pic below for my latest join. It still takes me a second or two it get the tip at the right place after pulling the trigger, so there's a bit a splatter.

As others have pointed out, the outlet or circuit makes a big difference in getting enough heat. The welder work much better on a 20amp circuit.

I could not find a 10 gauge extension cord at the local hardware stores, so I made my own using flexible (and somewhat expensive) 10 gauge wire with heavy duty plugs:

http://photos-d.ak.fbcdn.net/photos-ak-snc1/v1980/91/74/1506353441/n1506353441_155483_7308.jpg

Here the join that I've just about cleaned up:

http://photos-c.ak.fbcdn.net/photos-ak-snc1/v1980/91/74/1506353441/n1506353441_155482_7049.jpg

http://photos-e.ak.fbcdn.net/photos-ak-snc1/v1980/91/74/1506353441/n1506353441_155484_7569.jpg

http://photos-f.ak.fbcdn.net/photos-ak-snc1/v1980/91/74/1506353441/n1506353441_155485_7839.jpg

Thanks again for all your help.

t.

trikeman
01-13-2009, 12:19 AM
Now you're cooking!!!

I think one of the reasons so many welders diss the 120v wire feeders is because so many people try to use them on very sub-optimal circuits. With 230v it doesn't make nearly as much difference, since you have half the current flowing on the high side and generally more power to spare. Once you get a little 120v unit dialed in and on a good circuit its amazing what you can do with it.

rickairmed
01-13-2009, 12:22 AM
Tomas your getting better every time I see your pics :D. The extension cord will help alot I have an 8ga one for my 220 MIG for other guys who would like to make one you are looking for SO cord at home depot or lowes it will be in the area where they sell wire by the foot. The spatter is also one of the joys of fluxcore wire it will get better with practice but wont ever go away completely.


Rick

trikeman
01-13-2009, 12:33 AM
One thing I found Rick was that it was cheaper for me to buy a 50' 10ga extension cord (those Yellow Heavy Duty ones) at HD or Lowes and cut the ends off and replace them with 20A ends, than to buy the wire by itself. Even after I bought the 20 Amp ends it was still cheaper. Then I found the RV 10ga cords at Harbor Freight and it really got cost-effective.

I run my old 230V Miller Thunderbolt off a 50 foot extension I made from 10ga and it seems to work fine on my dryer 30 Amp circuit. Fortunately my dryer is next to the window facing my backyard so its an easy drop outside. I have index-finger-thick copper 50 foot leads that came with the welder (one advantage of buying used) on that welder and it still is way hot enough for what I need. Its nice to be able to weld in the backyard without having to move the welder off my back porch, although you get a pretty good workout carrying that much copper around :)

rickairmed
01-19-2009, 03:08 PM
Tomas hows your welding comming have you built anything yet :D.

Rick

tomas
01-27-2009, 12:21 AM
Tomas hows your welding comming have you built anything yet :D.
Rick

Well, I'm certainly getting closer to building somein'.
I've been rudely interrupted with my big project by stuff happening at work and with the old family.

But here's what I've been up to:

As we all talked about the 90amp flux core box wants CURRENT. So I extended a 20amp dedicated circuit into the garage with 12 gauge. It was better, but after a couple of (even) more test welds I thought it could be even more better! So I ripped out my newly installed 12 gauge wiring and put in 10 gauge. NOW WE'RE COOKING BABY!

In fact I figured I should try something fancy on an actual bike tube.
I just wanted to join the L-shape to the tube. The join was pretty solid, except for where I burned through the tube:

http://photos-b.ak.fbcdn.net/photos-ak-snc1/v1976/91/74/1506353441/n1506353441_163185_4704.jpg

Here's the other side:

http://photos-a.ak.fbcdn.net/photos-ak-snc1/v1976/91/74/1506353441/n1506353441_163184_4205.jpg


Yet another test join:

http://photos-h.ak.fbcdn.net/photos-ak-snc1/v1976/91/74/1506353441/n1506353441_163183_3724.jpg

After the clean-up, angle grinding work:

http://photos-c.ak.fbcdn.net/photos-ak-snc1/v1976/91/74/1506353441/n1506353441_163186_5196.jpg

Bisected:

http://photos-f.ak.fbcdn.net/photos-ak-snc1/v1976/91/74/1506353441/n1506353441_163189_4271.jpg

I got welder's flash. I read about the 'sand poring into the eyes' stuff and thought it was kind of BS. But that's pretty much what it felt like.

I think it may of been from looking at the glowing weld too soon after turning off the welder and lifting the helmet. It may have nothing to do with the helmet, but I completely broke down and got this:

http://www.millerwelds.com/products/weldinghelmets/performance.php

I went for the black, no flaming decals for me. It's by far the most expensive item I've bought yet for this project. Hopefully it'll last me a long time.

Eye sensitivity is probably different for everyone but I found the 10 shade of the old helmet not enough protection. With this miller helmet I can change the setting between shade 8 to 13. I'm find myself keeping it at shade 12.

I'm just digging myself in deeper here, but am having a blast. I have a bunch of welding projects lined up, between the jeep, bike mods, and hopefully, finally the Streefox..

Thanks again for all your help, I'll post any progress. It'll be in fits and starts.

t.

rickairmed
01-27-2009, 12:35 AM
Tomas good to hear from you also good to see your still at it . I think you will be happy for many years with that welding hood . I have a Miller big window elite and love it . I will admit I picked it up second hand ( hardly used) it still had the original lense protectors in it for about half price from a buddy over at SFT . I see you have learned how to blow through steel ( now the fun lesson filling in the holes you blew through the steel this is a lesson you will have to learn eventually as it will happen again . I still blow holes from time to time . When filling the holes back in do it slowly so as not to build up to much heat and blow through again.run a little bead on the edge of the hole LET IT COOL then run another bead and repeat as needed till the hole is filled :D. Welders flash is best dealt with with sliced potatoes see the thread on it here . I look forward to seeing more progress . I will have to remember to put up some pics of the tables and things I have stuck together with a welder ( they are great for getting SWMBO to give you more time in the shop ) :D.


Rick

tomas
01-27-2009, 12:42 AM
When filling the holes back in do it slowly so as not to build up to much heat and blow through again.run a little bead on the edge of the hole LET IT COOL then run another bead and repeat as needed till the hole is filled :D.
Rick

Build and cool, build and cool, makes sense, I will try it.
Yes, my first attempt to fill the hole resulted in a bigger hole..

I had to looked up swmbo on urbandictionary.com. Very funny, I got one of those.

As always, thanks again for the pointers.

t.

rickairmed
01-27-2009, 12:47 AM
Tomas no problem at all by the way if you have a compressor then cooling can be done quicker by blowing compressed air onto the weld bead before adding more to it . The buildup technique is meant mainly for filling hloes that were blown in thin metal not for initial welds .

Rick

macka
01-27-2009, 08:36 PM
Rick,

unless you have a filter/dehumidifier, blowing air on prepped metal can contaminate it accidentally.

rickairmed
01-27-2009, 08:47 PM
Macka I have air dryers and filters on my system but honstly unless you are tig welding your not going to hurt anything .

Rick

rickairmed
02-22-2009, 03:27 PM
Tomas havent heard from you in a while how is the practice comming are you still sticking things together over there :D.

Rick

tomas
03-02-2009, 08:54 AM
Thanks for asking Rick,

Some of the usual life/job stuff came up. One being my garage got flooded. So some clean-up and re-organization is needed, blah, blah...

I did manage to visit a great local steel supply place (Sullivan Metals, Holyoke, Mass http://www.sullivanmetals.com ). Soon I hope to buy my first 24 foot piece of 1.5 square tubing. Spring is coming! Right?

t.



Tomas havent heard from you in a while how is the practice comming are you still sticking things together over there :D.

Rick

rickairmed
03-02-2009, 10:08 AM
Tomas sorry to hear about the garage hope it didnt hurt anything . Good to hear you found a good steel supplier locally hopefully you will be able to gt the garage back in order and get back to it so you can have a bent to ride this spring :D.

Rick

Richie Rich
03-02-2009, 01:22 PM
Tomas....I hope the flood damage wasn't too great. I had some minor flooding once, and cleanup wasn't fun at all.

As for the steel, I wish Sullivan's was closer to me. It looks like they have everything you'll need.

I use Turner Steel in West Bridgewater which is the closest supplier to me but isn't as big as Sullivan's. It's lotsa fun driving home with 2 12-footers sticking out the back of the van...!!

http://www.turnersteelcoinc.com/

Best of luck with the project.

...Richie...

rickairmed
03-02-2009, 02:28 PM
Richie I take my chop saw with me to the steel supplier here as they sell in 20' lengths and cut them in half 10 footers will fit in the back of my van just fine you might try that for yours and cut them down to 6' if 12 footers wont fit in your van .


Rick

Richie Rich
03-02-2009, 10:15 PM
Good idea, Rick.....
They sell the square stock in 24-foot lengths and give you one free cut.
It's a 45-minute ride in traffic, so I have flags tied on the ends hoping no one will ram me and get a radiator full of steel...!! :mad:

I'll bring my handy-dandy saw with me the next time.

Thanks.........Richie >>
.

rickairmed
03-02-2009, 10:25 PM
RR no problem at all I have actually gotten 24' lengths but I am able to slip them over the headache rack in the van to get them in if cut in half my steel supplier actually suggested it to me as this way they dont have to tie someone up to cut it plus they dont have to charge me for cuts .


Rick

macka
03-03-2009, 06:50 AM
I bought a length of 2x6 and chopped it at 6 foot intervals, I'm making some bush bumpers for a friend. It's paying for material for a build.