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Hits: 937
Size: 74.72 KB
Posted: 11/28/05
I got a good deal on unused 24"x32" 1/4" plates at scrap price, so they'll be used for a number of t... | 
Hits: 411
Size: 42.03 KB
Posted: 11/28/05
Even with only about 50% weld penetration (a single 1/8" MIG bead), the plate still has no trouble h... | 
Hits: 366
Size: 71.71 KB
Posted: 11/28/05
New bumper endplates cooling after being cut out of 1/2" plate with the torch. Lots of cleanup stil... | 
Hits: 353
Size: 43.88 KB
Posted: 12/12/05
Putting a square peg through a round hole ... | 
Hits: 356
Size: 47.52 KB
Posted: 12/12/05
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Hits: 334
Size: 60.39 KB
Posted: 12/12/05
JB drilling the end plates. | 
Hits: 406
Size: 45.23 KB
Posted: 12/12/05
Gussets tacked in place, one test bead run. | 
Hits: 415
Size: 51.68 KB
Posted: 12/12/05
Lots of spatter and not the best penetration, but the remainder of this piece is overengineered. I'... | 
Hits: 393
Size: 50.15 KB
Posted: 12/12/05
Pretty good heat affected zones on the backside, but the tack in the foreground is ugly as hell. | 
Hits: 386
Size: 53.75 KB
Posted: 12/12/05
Backside cooling down after finish welding. |
Hits: 431
Size: 61.41 KB
Posted: 12/12/05
Business end of the bumper. Welds around the receiver tube are three pass fillet, chain plate is fi... | 
Hits: 500
Size: 46.1 KB
Posted: 12/12/05
I'd been fighting my welder the whole time, and like an idiot couldn't figure out why I was having t... | 
Hits: 541
Size: 62.52 KB
Posted: 12/12/05
Time to make the final cut to length so we can mount the bumper between the endplates. Daddy's got ... | 
Hits: 1812
Size: 64.21 KB
Posted: 12/12/05
Tacked in place and ready to be unbolted for final welding. Right now it's secured by half the endp... | 
Hits: 727
Size: 54.05 KB
Posted: 1/3/06
Finish welds on the end plates. |
Hits: 625
Size: 57.38 KB
Posted: 1/3/06
All done except the top plate and the reinforcement around the shackle points. Oh, and still need f... | 
Hits: 470
Size: 32.24 KB
Posted: 3/6/06
With a little cleanup, these two rough ovals will become the reinforcement for the rear shackle poin... | 
Hits: 479
Size: 61.69 KB
Posted: 3/6/06
A "little" cleanup. New toy makes short work of rough edges on a pair of plates that total 1" when ... | 
Hits: 457
Size: 39.6 KB
Posted: 3/6/06
Plates are drilled, then beveled at the ends and tacked in place ... | 
Hits: 536
Size: 42.03 KB
Posted: 3/6/06
Followed by finish welds. Single pass 5/32" or so fillets are more than sufficient for the required... |
Hits: 544
Size: 42.7 KB
Posted: 3/6/06
... which is good, since that's the maximum capacity of this welder in a single pass. More strength... | 
Hits: 562
Size: 45.21 KB
Posted: 3/6/06
The infill at the end. I did screw up doing the bevel on the opposite end, and had to grind out abo... | 
Hits: 708
Size: 64.83 KB
Posted: 3/6/06
Two endplates, plus four tabs to help support the skidplate. Then we quit on the truck for the day ... | 
Hits: 708
Size: 73.5 KB
Posted: 3/7/06
I was asked for calcs and an illustration explaining why I said the factory mounting holes in the fr... | 
Hits: 778
Size: 24.28 KB
Posted: 3/7/06
Illustration of the block shear failure area, and necessary dimensions. |
Hits: 665
Size: 24.14 KB
Posted: 3/7/06
Illustration of the rotation failure dimensions. | 
Hits: 551
Size: 27.41 KB
Posted: 3/13/06
Design for a simple removable winch mount, much stronger than receiver mount and without the clearan... | 
Hits: 500
Size: 51.18 KB
Posted: 3/17/06
We had a discussion on T4W about doing big jobs with a little welder. Here's an illustrative series... | 
Hits: 517
Size: 55.31 KB
Posted: 3/17/06
Get the pieces lined up straight and clamped in place. Remember the typical MIG guidance about not... | 
Hits: 495
Size: 45.95 KB
Posted: 3/17/06
Then strip back the paint at the weld area, and clean. That filth on the paper towel was from one s... |
Hits: 511
Size: 52.04 KB
Posted: 3/17/06
Tack it up ... | 
Hits: 504
Size: 37.42 KB
Posted: 3/17/06
Then connect the dots. In this shot, I've just finished the middle section, as you can see. I had ... | 
Hits: 404
Size: 43.09 KB
Posted: 3/17/06
If you want decent penetration, don't ask the welder to do more than it can. Going slow just piles ... | 
Hits: 449
Size: 43.95 KB
Posted: 3/17/06
Run the second bead on the right side. My garage was a high traffic area at this point, so even wit... | 
Hits: 455
Size: 45.69 KB
Posted: 3/17/06
Run the lefthand bead. Fewer stops this time, too, which is good since it's easy to trap small pock... |
Hits: 499
Size: 51.96 KB
Posted: 3/17/06
Now, flip it over and get a look at the backside (I've already given the plate time to cool and clea... | 
Hits: 497
Size: 37.03 KB
Posted: 3/17/06
Tilt your 4-1/2" angle grinder up 45* and V out the backside. Start with the worst spot, and open i... | 
Hits: 458
Size: 49.24 KB
Posted: 3/17/06
A single fast pass will finish the backside. I probably could've skipped these last steps if I were... | 
Hits: 513
Size: 44.7 KB
Posted: 3/17/06
But I'm grinding this plate smooth on both sides, because it's highly visible.
Where's the weld... | 
Hits: 433
Size: 44.98 KB
Posted: 3/17/06
I need a 2-1/2" flange at the backside of this plate, so we decided to see if we could clamp itt, he... |
Hits: 374
Size: 47.28 KB
Posted: 3/17/06
Not a chance! Of course, if I'd known last weekend how Dave was doing his bends I could've done tha... | 
Hits: 376
Size: 39.23 KB
Posted: 4/2/06
Alright, here's the forward side of our new reinforcing flange, a 2x2x1/8 angle. These PL2x2x3/16 p... | 
Hits: 357
Size: 43.57 KB
Posted: 4/2/06
First pass down the root of the fillet complete. Honestly, I could probably have left it like this.... | 
Hits: 519
Size: 38.21 KB
Posted: 4/2/06
Three more passes complete the fillet. Trying to keep it hot and fast as I can. | 
Hits: 508
Size: 48.84 KB
Posted: 4/2/06
Another two passes to finish the weld of the endplate to the winch plate. Note the little bit of po... |
Hits: 447
Size: 35.39 KB
Posted: 4/2/06
Opposite endplate, likewise three passes below and one on the top. | 
Hits: 588
Size: 63.47 KB
Posted: 4/2/06
The whole stiffened winch plate assembly, flipped upside down end for end so I can clean the bottom.... | 
Hits: 1171
Size: 64.07 KB
Posted: 4/2/06
Back where it should be, with areas to be welded now cleaned of paint and grime. Just needs to be c... | 
Hits: 415
Size: 63.39 KB
Posted: 4/2/06
After screwing around with the little MIG welder all morning, I decided I should really use the weld... | 
Hits: 443
Size: 62.76 KB
Posted: 4/2/06
Still haven't chipped the slag from the last rod. Not the prettiest thing in the world, but I could... |
Hits: 422
Size: 65.69 KB
Posted: 4/2/06
I really need to spend a lot more time practicing with the big arc welder. I think I'd end up getti... | 
Hits: 339
Size: 61.2 KB
Posted: 4/2/06
One of the areas I ended up having to grind porosity and run a second pass on. I ended up deciding ... | 
Hits: 437
Size: 73.59 KB
Posted: 4/2/06
Another section of the area where I did two passes. Still need to work on my rod control and get a ... | | |
Rear skidplate & Bumper