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Unfortunately the idea to further document my job creation was an after thought. If I had thought it through beforehand, I would have snapped a few more pictures of the clamps, for a little where to clamp and why. I hope you have a vivid imagination when you picture what I will describe to you later in this article.
Before I submitted my job estimate, I checked my inventory of steel stock to be sure I actually had the materials I would need for the job. Lucky thing I did, its a big savings in that I didn't have to purchase anything but the consumebles, eg.. the welding rod and gas for the generator/welder that the company rented for me to use.
The core of this project is to extend the frame of this machine by roughly 13/16 ". this is going to explain why the machine is split the way it was. Underneath the bottom of the pheonix is a 1/2" plate welded 3" - 5" center weld pattern around the baseplate.
On the backside of the same bottom tube is another plate tapped for anchor mounts. That one is thicker by 1/4", and overlapped the bottom plate by 3". I chose to split the bottom tube 1st by cutting through the tube but not all the way across the baseplate. In the after pictures you can see the baseplate was approximatrly 6" wide and protrudes 3" in front of the base tube.
The 2" tubes above were then flush cut leaving 5 - 10 thousandths or so of the tube for easy relocation when I scribe my marks that I will use to make sure everything realiegns prior to tackin it in place.
A length of 3"x3" angle clamped to the baseplate ensures the least possible warpage when I weld the overhead weld from under the base first. I know I will get more pull up when I pour the heat on the top side 2nd because of the virticle element of the tube. I must return and clean out any excess to ensure a 1/16" root gap between the tube and insert. I then stick the tip of a screwdriver like a wedge in the top, and tack both ends of the gap on the inside of the tube.
Note Tack the sides as well. Now you can easily weld inside and out if you so chose as I did. It is part of that meet or exceed customers expectations thing, you know?
The base will now be the main support when I need to bring the two pieces back together. That length of 3x3 clamped accross the front face of the tube will ensure the basic aliegnment is maintained.
<>>Similar procees of clapms and angle to aliegn plus thed on the inside of the tube will add an extra burnoff of any paint on the outside.
I'm reminded of the little flame I snuffed from a spark in some oily corner on that frame. Be careful out there!
Too many times I have gone on twitter.com/#welders and read a story of a fire caused by welder sparks. If you are contracting, remember to ask if you need to forward your information for a hotwork Tag or some type of similar paper trail. <>
Now on to the story of day 2 on this project. Day 2 started out down in the shed sawing the tube inserts, the flat stock that see in the picture above. I know, they didn't show up too well so no I saw no need to forward this one, maybe next time I'll consider the background.
3/8" x 18 and 1/2"x 16 tpi nuts were welded in place on the 4 tabs and 2 push bar supports. I countersink the holes and bolted tightly to ensure center on hole and keeps the threads clean while I weld them with my 112vlt mig welder .030 ga wire, at home, prior to picking up the welder from the rental center before it closes at 5:00 PM.
The 2 tabs and 2 supports were welded before I brought the two halves back together. then I lifted the lighter halve to rest on the baseplate as describe earlier.
4 angles 5 ft long with 8 6" c-clamps holds the two square on both the upper and lower tubes. Remember diagonal measurements!
2 turns with the ratchet in the left front corner adjustment brings my scribe mark to the virticle just like new.
Tack the base tube, double check measurements, hmm.. tack top, double check again, snugged up tight by a 1/16th hmm.. one good thump with thor, my pet hammer, double check again, HA! perfect! retack to lock it up!
The majority of the frame was welded prior to the clamps and the jackstands being removed.
I confess I under estimated the time required for the ark welding process not thinking of slag chippin but I was satisfied having it finished in 8 hours, thats every thing,prep work, the measuring, clamping, the welding, cleaning, and touch up paint applied.
My goal is now to pack up for tonight, catch a nap and return the welder for an overnight charge instead of the 2 day or weekly rate I had estimated. Another savings I can pass on to my customer.
At the end of day 2 I have exceeded my estimated hours and calculated my estimated earnings fell 8 hours at this point when I include, the daily reporting, phone tag, and rental running.
It's ok, this project is gonna be finished tonight and I'm lookin forward to that "mission accomplished" message I'm gonna send when I get home.
