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I welded aluminum today
The rear window/frame on my pickup trucks shell is about 15 or so
years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
I must say that was one of the best bits of spontaneous writing I have
ever witnessed. 2 thumbs up and I actually still have 2 thumbs You are one clever feller and a crafty wordsmith and a smith in the other sense. Have a happy life. Melt some aluminum for all of us. Hey it's fun and the most abundant element on earth so why not melt it,.? The earth is gonna do it anyway.... |
I welded aluminum today
In article ,
Gunner Asch wrote: The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. One heckuva story, Gunner! Well done! |
I welded aluminum today
Gunner Asch wrote: Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Didn't the cats applaud and hold up little signs like 7.9, 8.0, 7.8, 8.4, 8.2 ? Ron |
I welded aluminum today
good deal. So funny its gotta be true...
Gunner Asch wrote: The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
Gunner,
I've been wanting to try my hand at welding aluminum for a while now. Haven't really had a need to, but just something a person so led has to try. Just ask you. Now, with all your encouragement, I think I can ......... wait a little while longer. I'll have to wait a little bit, anyway. Everytime I'd start, your story would come to mind and I wouldn't be able to hold the torch steady for laughing so hard. Great tale. Somewhere twixt Twain and O'Henry. Respectfully, Ron Moore "Gunner Asch" wrote in message ... The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
Gunner Asch wrote:
Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Definitely a rcm classic. Thanks for writing it out... |
I welded aluminum today
"Jim Stewart" wrote: Definitely a rcm classic. Thanks for writing it out... ^^^^^^^^^^^^^^^^ Gunner, if any of this is made-up, you lose some points, but gain them back for imagination. BTW, this is an example of why I haven't "plonked" you, in spite of the vast difference in our social and political outlooks. That, and the fact that I am also a cat lover. |
I welded aluminum today
On Mon, 28 Nov 2005 08:49:49 GMT, Gunner Asch
wrote: snip a good story What's so sad about this is how close to home this comes. I spent a whole day under a belly dump grain trailer a while back dodging hot balls of aluminum. I definitely wasn't in a good enough mood to write something like that when I got out. As for the foot pedal thing I know where you're coming from there as well. I got a hose reel for my torch the other day and while I was putting the handle on I dropped a screw. I went to the floor trying to find it in all the junk that had collected up under my temporary table (I guess it's temporary, I've not managed to get it out of the shop for a few months now). I was down there minding my own business hunting for the screw when the outlaw hose reel decided to try and do me in. It rolled off the table hit me in the head and then proceeded to try to break my thumb. Reeling from the double blow it took me a few minutes to recover and figure out what happened. I fixed it though. I quickly bolted it down in lockup on the side of my welder. I figure its in there for life. ;-) Wayne Cook Shamrock, TX http://members.dslextreme.com/users/waynecook/index.htm |
I welded aluminum today
On Mon, 28 Nov 2005 14:12:47 GMT, Ignoramus4324
wrote: Outstanding! Does your truck still start? Is all electronics still working? i Yup..and the window doesnt bobble anymore!! Yay!! Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
On 28 Nov 2005 07:00:08 -0800, "doo" wrote:
Gunner Asch wrote: Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Didn't the cats applaud and hold up little signs like 7.9, 8.0, 7.8, 8.4, 8.2 ? Ron Cats? You evidently dont have cats... The best they will do is a mildly disinterested glance..followed by some tounge grooming, a yawn and several hours of sleep. Maybe..just maybe...a tail flick to indicate approval..if you are lucky. Not exactly an interested audience G Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
On Mon, 28 Nov, Gunner Asch wrote:
[ snip ] Thanks for that. Closest I've come to something like this was when I decided to weld while wearing sneakers with mesh over the toe area. A piece of slag flew and went right through the mesh, right through my thin cotton sock, and lodged in between two toes. I was hopping around pretty wildly for a bit. Gunner, consider wearing a cup for all overhead welding operations from now on. :-) --Donnie -- Donnie Barnes http://www.donniebarnes.com 879. V. |
I welded aluminum today
Gunner Asch wrote: a hilarious story about welding
Gunner, that was great! Although I'm surprised you didn't just chuck the truck in the 4-jaw of your 80"x264" lathe and turn it over to do the welding. (Not that I'm envious of your Stuff collection or anything ...) I sent the story to my daughter in college, cheered her up before finals. Thanks. -- Fred R ________________ Drop TROU to email. |
I welded aluminum today
On Mon, 28 Nov 2005 18:48:47 GMT, Gunner Asch
wrote: On 28 Nov 2005 07:00:08 -0800, "doo" wrote: Gunner Asch wrote: Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Didn't the cats applaud and hold up little signs like 7.9, 8.0, 7.8, 8.4, 8.2 ? Ron Cats? You evidently dont have cats... The best they will do is a mildly disinterested glance..followed by some tounge grooming, a yawn and several hours of sleep. Maybe..just maybe...a tail flick to indicate approval..if you are lucky. Not exactly an interested audience G They have probably seen it all before :-) Great story btw, been there done some of it! -- |
I welded aluminum today
Gunner Asch wrote:
SNIP Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. SNIP Damn!!! Years of being careful & I finally snarfed coffee on the keyboard (& my lap warmer. She still has claws, as my leg can attest). Great story, Gunner. -- Steve Walker (remove wallet to reply) |
I welded aluminum today
On Mon, 28 Nov 2005 18:19:12 GMT, "Leo Lichtman"
wrote: "Jim Stewart" wrote: Definitely a rcm classic. Thanks for writing it out... ^^^^^^^^^^^^^^^^ Gunner, if any of this is made-up, you lose some points, but gain them back for imagination. BTW, this is an example of why I haven't "plonked" you, in spite of the vast difference in our social and political outlooks. That, and the fact that I am also a cat lover. Actually all true. Im all too often laughing at my own screw ups..which may be a good mental health thing..but like learning from your mistakes..it only teaches you when to cringe the next time.... G Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
Gunner Asch wrote:
The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner Hell of a story, next time you try something new setup the video camera first. If there is still a home video program running somewhere you might be able to buy some new gear with the winnings. I tried to weld aluminum this past weekend... Unfortunately the power situation in my shop sucks and all I did was trip the breaker. I get away with it for welding in 1/8" steel, but 1/4" AL just needs too much power. I've really got to upgrade the feed and panels. Pete C. |
I welded aluminum today
Way to go Gunner - more than one Yahoo for you and I bet you said it more
than once. (other words deleted for the light hearted) :-) Working away on my CNC plasma system - tons of cutting - cut 31 panthers out at 2.5 seconds each. Ripping speed. In 7075-T6 Al naturally. Martin Eastburn @ home at Lions' Lair with our computer lionslair at consolidated dot net NRA LOH, NRA Life NRA Second Amendment Task Force Charter Founder Gunner Asch wrote: The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner ----== Posted via Newsfeeds.Com - Unlimited-Unrestricted-Secure Usenet News==---- http://www.newsfeeds.com The #1 Newsgroup Service in the World! 120,000+ Newsgroups ----= East and West-Coast Server Farms - Total Privacy via Encryption =---- |
I welded aluminum today
Sounds like SANTA needs to find a pith helmet or a hard hat for Wayne
and a torch handle thumb wheel to replace the foot pedal! Big E as I was once called in my younger years has both! Find the helmet hard to wear cutting trees or working in the shop. Standing around like a pit boss is fun. Martin Eastburn @ home at Lions' Lair with our computer lionslair at consolidated dot net NRA LOH, NRA Life NRA Second Amendment Task Force Charter Founder Wayne Cook wrote: On Mon, 28 Nov 2005 08:49:49 GMT, Gunner Asch wrote: snip a good story What's so sad about this is how close to home this comes. I spent a whole day under a belly dump grain trailer a while back dodging hot balls of aluminum. I definitely wasn't in a good enough mood to write something like that when I got out. As for the foot pedal thing I know where you're coming from there as well. I got a hose reel for my torch the other day and while I was putting the handle on I dropped a screw. I went to the floor trying to find it in all the junk that had collected up under my temporary table (I guess it's temporary, I've not managed to get it out of the shop for a few months now). I was down there minding my own business hunting for the screw when the outlaw hose reel decided to try and do me in. It rolled off the table hit me in the head and then proceeded to try to break my thumb. Reeling from the double blow it took me a few minutes to recover and figure out what happened. I fixed it though. I quickly bolted it down in lockup on the side of my welder. I figure its in there for life. ;-) Wayne Cook Shamrock, TX http://members.dslextreme.com/users/waynecook/index.htm ----== Posted via Newsfeeds.Com - Unlimited-Unrestricted-Secure Usenet News==---- http://www.newsfeeds.com The #1 Newsgroup Service in the World! 120,000+ Newsgroups ----= East and West-Coast Server Farms - Total Privacy via Encryption =---- |
I welded aluminum today
"Donnie Barnes" wrote in message main... Gunner, consider wearing a cup for all overhead welding operations from now on. :-) Would he need a leather cup? If so, I think he's going to need to come up to San Francisco to get one. I think his only choice is likely to be black leather with studs on it. I'm not sure I'd want to be around when he suits up for welding... Yesterday I needed to TIG a couple of small pieces together and did it with my latex gloves on. Of course I grabbed the hot end of the filler rod with my torch hand in order to move a piece with my filler rod hand. I doubt I looked as dramatic as Gunner, but I'm betting we said some of the same words. Peter |
I welded aluminum today
I think I better make a double sided half dollar now.
Prolly start with a penny and work my up Gotta search the couch Oh here it is. i alredy have one no wait... it's a pocket watch looked like a coin fer a moment don't we all look like coins fer a moment? A phrase well coined will surely brighten someone.... and is that not what we are here for essentialy? Thank you all for the wisdom you have shared and letting me spew this utter nonsense occasionaly. Go commit some building on someones life. Gravity gets in the way. A wise woman once said... well, I can't think of a wise woman right now hasta la vista danny |
I welded aluminum today
The only way I could reach the crack, was sitting tailor fashion on
the tailgate, facing the front of the truck and working overhead... Gunner, Congratulations. You've found a position not mentioned in the Kama Sutra. ohm padme padme hum... ohm padme padme hum VT |
I welded aluminum today
BTW, this is an example of why I haven't "plonked" you, in spite of
the vast difference in our social and political outlooks. That, and the fact that I am also a cat lover. I am convinced that this group is what God envisioned when Man wrote "diversity" into the law! Unfortunately, Man didn't grasp the concept... But this is my all-time favorite newsgroup... except when somebody tells me I'll get sued to Ruwanda for putting up a building with salvage trusses.... This welding asylum reminds me of that country western song "I love this bar". Gentlemen, start your welders! Vernon |
I welded aluminum today
On Mon, 28 Nov 2005 21:28:33 GMT, Gunner Asch
wrote: On Mon, 28 Nov 2005 18:19:12 GMT, "Leo Lichtman" wrote: "Jim Stewart" wrote: Definitely a rcm classic. Thanks for writing it out... ^^^^^^^^^^^^^^^^ Gunner, if any of this is made-up, you lose some points, but gain them back for imagination. BTW, this is an example of why I haven't "plonked" you, in spite of the vast difference in our social and political outlooks. That, and the fact that I am also a cat lover. Actually all true. Im all too often laughing at my own screw ups..which may be a good mental health thing..but like learning from your mistakes..it only teaches you when to cringe the next time.... G Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner LOL, me also. Many, if not most times I have no helper and things can get down right unforgettable. Onward through the fog comes to mind. |
I welded aluminum today
Cats? You evidently dont have cats...
Yep, got cats... 4 of 'em. For some reason though, Monty Python's Confuse-A-Cat skit came to mind when I read your post..LOL. And reminds me of the time a co-worker was TIGging a part, went to reposition the part, and sat the torch in his lap, accidentally hit the pedal...YEP, zapped him right on the 'lil fireman! Youch! Funny thing to have to explain/show the company nurse. Ron |
I welded aluminum today
On Tue, 29 Nov 2005 02:25:33 GMT, "Peter Grey"
wrote: "Donnie Barnes" wrote in message omain... Gunner, consider wearing a cup for all overhead welding operations from now on. :-) Would he need a leather cup? If so, I think he's going to need to come up to San Francisco to get one. I think his only choice is likely to be black leather with studs on it. I'm not sure I'd want to be around when he suits up for welding... Im closer to West Hollywood. Where barbed wire and dog collars are considered Marital Aids..... I wonder how many here have seen a 400lbs fellow in minimal leather attire, on a leash, held by a 5'2", 100 lb minimally leather attired androgenous woman/guy. West Hollywood..got to love it if you are secure in your pyche..will run screaming from it if you are sheltered.... Yesterday I needed to TIG a couple of small pieces together and did it with my latex gloves on. Of course I grabbed the hot end of the filler rod with my torch hand in order to move a piece with my filler rod hand. I doubt I looked as dramatic as Gunner, but I'm betting we said some of the same words. Peter Indeed. My little submission was heavily ediited as befits a family group. Id exhausted most of my Anglo-Saxon adjetives, was well into the ones from SEA, interspersed with the Germanic ones. seasoned with Finnish ones... Sigh.....its always funnier after the fact..... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
Gunner, congrats, and thanks for the laughs.
I know the pain of which you speak, hence why I can laugh about it In article , Gunner Asch wrote: The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner -- "I love deadlines, especially the wooshing sound they make as they fly by" - Douglas Adams |
I welded aluminum today
On Mon, 28 Nov 2005 08:49:49 GMT, Gunner Asch
wrote: But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. Damn betcha. When the ol' dawg can't learn new tricks it's end game. Keep a round in the spout in case you're unlucky enough not to check out sooner. |
I welded aluminum today
On Tue, 29 Nov 2005 01:17:30 -0600, Don Foreman
wrote: On Mon, 28 Nov 2005 08:49:49 GMT, Gunner Asch wrote: But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. Damn betcha. When the ol' dawg can't learn new tricks it's end game. Keep a round in the spout in case you're unlucky enough not to check out sooner. My living will is quite specific on that issue. The day I stop learning is the day before they kick dirt over my box. Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
On Mon, 28 Nov 2005 14:12:47 GMT, Ignoramus4324
wrote: Outstanding! Does your truck still start? Is all electronics still working? i Yup..and the window doesnt bobble anymore!! Yay!! Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner TeeHee... just don't mount any spare tires to it.... G Ken. |
I welded aluminum today
Now this leads to to the question...
Can you teach a cat to weld? Will their little paws actually hold the tig torch? They have the sight definition but can you get an auto dark helmet for a cat? Why build robots when we already have cats? Something to ponder.... |
I welded aluminum today
"Wayne Cook" wrote in message ... On Mon, 28 Nov 2005 08:49:49 GMT, Gunner Asch wrote: snip a good story What's so sad about this is how close to home this comes. I spent a whole day under a belly dump grain trailer a while back dodging hot balls of aluminum. I definitely wasn't in a good enough mood to write something like that when I got out. For me it's my new pet project. I'm building a tank for use in paintball games. I'm not near good enough with a tig to tackle aluminum, but I still get into some interesting predicaments trying to weld at different angles and still reach the pedal. |
I welded aluminum today
Are you talking about an armored tank that moves on tracks, or a tank for air? If it is the former, I can sell you some 3/16" tungsten electrodes to make paintballs that would penetrate aluminum tanks. :) i I'm talking about an armored tank that moves on tracks . Except it's really more of an armored security vehicle modeled after the m1117 guardian. This is the 2nd one I've built. The first one looks a bit like a box on wheels although it does have twin axles with duel tires in the back. :) It sports a 3" main gun operating from CO2. It shoots 90 paintballs per shot. My new one is going to be more realistic looking if I ever get the time to finish it. It will have a semi auto main gun shooting foam "darts" of my own design. It will also have a 2400 round per minute chain gun shooting standard paintballs. As for your Armour piercing tungsten, I think I better pass. I've made a number of paintball "weapons" the most challenging part by far is making something that won't actually hurt somebody. :) |
I welded aluminum today
On Tue, 29 Nov 2005 02:25:33 GMT, with neither quill nor qualm, "Peter
Grey" quickly quoth: I said: Gunner, consider wearing a cup for all overhead welding operations from now on. :-) Would he need a leather cup? If so, I think he's going to need to come up to San Francisco to get one. I think his only choice is likely to be black leather with studs on it. I'm not sure I'd want to be around when he suits up for welding... Ditto the "somewhere else" feeling. g No, I meant a fiberglass cup so when the foot pedal hits him the next time... bseg I learned my lesson and got a HF leather apron before trying to weld the plate to my truck frame. I still need to get that done and will have to grind more of a miter on the thick angle iron section before doing so. But it has to stop raining before that. I don't want to be a nice ground for a stick welder, knowwhatimean,vern? Yesterday I needed to TIG a couple of small pieces together and did it with my latex gloves on. Of course I grabbed the hot end of the filler rod with my torch hand in order to move a piece with my filler rod hand. I doubt I looked as dramatic as Gunner, but I'm betting we said some of the same words. No doubt. I had a visit from the UPS guy last night in the dark. I ordered the $4 (delivered!) Miller welding calculator set. It'll be really handy! --- - Sarcasm is just one more service we offer. - http://diversify.com Web Applications |
I welded aluminum today
On Tue, 29 Nov 2005 11:28:08 GMT, Ken Sterling (Ken Sterling) wrote:
On Mon, 28 Nov 2005 14:12:47 GMT, Ignoramus4324 wrote: Outstanding! Does your truck still start? Is all electronics still working? i Yup..and the window doesnt bobble anymore!! Yay!! Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner TeeHee... just don't mount any spare tires to it.... G Ken. LOL...blush. After rebuilding the new spare tire carrier..and properly welding it using something other than a HF Mig..so far its held up nicely for about 80,000 miles. Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
I welded aluminum today
Gunner, you get 3 chuckles out of a maximum of 3. Been there, done
that. But not nearly quite the way you describe, although I have used every extrimety of my body and every possible possition known to man and God to squeeze my foot pedal together at one time or another. Still chuckling. Bill |
I welded aluminum today
Gunner Asch wrote:
So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. Congrats on the welding and a funny story! I had to clean a fair amount of my morning Pepsi off my shirt and monitor/keyboard from laughing at the wrong time. I have seen Nomex lined caps and Nomex lined gloves, I have not seen a Nomex lined codpiece. It might be marketable! I have had similar experiences with very "out of position" tig welding myself, including setting my jeans on fire. Keep laughing, Bob |
I welded aluminum today
On Tue, 29 Nov 2005 17:56:09 GMT, with neither quill nor qualm, Gunner
Asch quickly quoth: LOL...blush. After rebuilding the new spare tire carrier..and properly welding it using something other than a HF Mig..so far its held up nicely for about 80,000 miles. OhmyBuddha! You've put 80k miles on since posting that a year or two ago, Gunner? Amazing. P.S: Congrats on your newly-found non-lethal welding skills. ;) --- - Sarcasm is just one more service we offer. - http://diversify.com Web Applications |
I welded aluminum today
Terrific story. Yes, for an old dog burnt up chest hairs are acceptable
damage. But them jewels? Nope. Otherwise, a person would never try something dumb. ciao, David Todtman "Gunner Asch" wrote in message ... The rear window/frame on my pickup trucks shell is about 15 or so years old and is getting tired. The aluminum hinge/frame was starting a crack along the hinge assembly, and is composed of a chunk of L aluminum, about 1/16" thick. Not having any aluminum of the proper type on hand, Ive been pondering this for a couple weeks, and have been waiting for the entire window/hatch to fall off on the freeway....cringe. So today..in an insane moment of bravado and balls..I decided to TIG weld up the 12" long crack, and also reinforce other weak areas. So I drug the ground, tig torch, foot pedal and stainless steel brush over to the now backed intotheweldingarea pickem up truck..and thought about how to proceed. The crack was only acessable with the hatch open, and then from underneith. This meant I had to overhead weld the dreaded aluminum thin stuff...GACK!!!!! OMGODthisisgonna be a bitch..and it was. I fired up the Airco Squarewave 300, rounded a 3/32 2% lanthanated electrode (per Ernie) on a chunk of stainless steel, Electrode positive, then switched to AC, scrubbed the snot out of the aluminum with a SS wire brush..then pondered the first problem...foot pedal. The only way I could reach the crack, was sitting tailor fashion on the tailgate, facing the front of the truck and working overhead. No way to push the pedal..so I put it under my left thigh, and could push by moving my leg a bit. This of course lead to serious leg cramps..zapping myself with the HV at least once..sigh. The frame was insulated from truck ground by the fiberglass of the shell, so I didnt have to worry about zapping the computer etc..which was a small blessing. I started the arc..and started heating the aluminum..and found the current wasnt high enough, so I set it up for max 125 amps, with start current of 30%..made the best guess at the balance, backround and pulse, then assumed the position again..and again got a cramp..resulting in a flinch..sticking the electrode to the frame...sigh.. resharpening..I tried it again.. Pressing down with my leg..I could see the aluminum start to melt..and I fed in a little aluminum filler..which balled up, and fell onto my crotch. I could smell jeans burning...as I instantly fell off the tailgate in a desperate struggle to protect the family jewels. Now Im upside down, wrapped in ground cable, tig hose, the foot pedal teeters on the tailgate..then falls on my crotch. What the hot dingleberry didnt scorch..the pedal crushed. Sigh... Getting out my leather apron (hindsight is 2020)..I reassumed the position again..but a bit more gingerly...I fired up the arc again..this time waiting for the base metal to start to go all silvery, then gently dabbed the filler into the silver puddle... SOB...it melted into the puddle..and stayed there...**** me running..its working!!! Im welding Im welding! Buawahahahhaha! Paying close attention..I managed to run at least 10" of the 12" with a clean, neat bead. Not stack of dimes..but still nice (for me). Then I got a leg cramp, stuck the electrode into the puddle..filled the entire cup of the torch with melted aluminum and fell off the tailgate again as the cup exploded, raining hot **** all over me..including under my mask, down my neck. But my crotch was protected!!!! Sigh..... Brush off the singed chest hair, installed a new cup, regrind of the electrode, reposition, scrub vigorously with the brush again, fire up the arc, and finish the weld in a pretty matter of fact fashion..forgetting of course to creep up on the end of the material..and melting the last 1/4" completly, down into the cup of my torch again..which fortunately didnt explode this time. Well Ill be damned..I actually overhead welded aluminum. Mostly. Had some icicles hanging, there at the end of the weld..which I took care of with a 4 flute 1/4" endmill in an air die grinder..worked really slick. If Id been smart..and had a helper, I should have taken the 30 minutes to pull the shell off the truck, and turned it over..but hey..Ive been called a lot of things..but never smart..and there wasnt a helper handy. Now I can reeeeely understand the utility value of one of those torch mounted controls and why spool guns are so popular. I have a mig..but not the proper liner etc etc though I do have several spools of aluminum mig wire (which I was using for filler.) But Im totally tickled..Ive gone from Daubers Helper, to Daubers Apprentice 1. Maybe an old dog can learn new tricks. This just opened up a whole new can of worms for me..now that I can melt aluminum together. Sorta. Kinda. A little. Somewhat...... Gunner "Pax Americana is a philosophy. Hardly an empire. Making sure other people play nice and dont kill each other (and us) off in job lots is hardly empire building, particularly when you give them self determination under "play nice" rules. Think of it as having your older brother knock the **** out of you for torturing the cat." Gunner |
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