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 Post subject: Re: Welding School / build thread.
PostPosted: Fri Mar 27, 2015 12:37 am 
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Hey guys, thanks for the kind words. I'm really into MIG, it's like cheating compared to some 7018 rods from the year 400 B.C. Once I get set up in the garage at the new apartment Im moving into soon, I'll mock up a cardboard bumper and then see if I can get my hands on some 1/4" plate. Thought about using 3/8" at first then realized I'm not driving an F350.. :lol:

What thickness is your KK bumper Helm?

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OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
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 Post subject: Re: Welding School / build thread.
PostPosted: Fri Mar 27, 2015 6:07 am 
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Here's the details on ATH's bumper

viewtopic.php?f=34&t=77091

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 Post subject: Re: Welding School / build thread.
PostPosted: Fri Mar 27, 2015 11:23 am 
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WHITE the civilian wrote:
Hey guys, thanks for the kind words. I'm really into MIG, it's like cheating compared to some 7018 rods from the year 400 B.C. Once I get set up in the garage at the new apartment Im moving into soon, I'll mock up a cardboard bumper and then see if I can get my hands on some 1/4" plate. Thought about using 3/8" at first then realized I'm not driving an F350.. :lol:

What thickness is your KK bumper Helm?

3/16" for the 'skin' and 1/4" for the mounts.. Pretty much the norm for bumpers.

1/4" for everything on your bumper will make it pretty heavy..

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 Post subject: Re: Welding School / build thread.
PostPosted: Fri Mar 27, 2015 4:20 pm 
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Atthehelm wrote:
WHITE the civilian wrote:
Hey guys, thanks for the kind words. I'm really into MIG, it's like cheating compared to some 7018 rods from the year 400 B.C. Once I get set up in the garage at the new apartment Im moving into soon, I'll mock up a cardboard bumper and then see if I can get my hands on some 1/4" plate. Thought about using 3/8" at first then realized I'm not driving an F350.. :lol:

What thickness is your KK bumper Helm?

3/16" for the 'skin' and 1/4" for the mounts.. Pretty much the norm for bumpers.

1/4" for everything on your bumper will make it pretty heavy..

The ones i build too are also 3/16" skin with 1/4" mounts and winch plate.

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.


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 Post subject: Re: Welding School / build thread.
PostPosted: Fri Mar 27, 2015 8:36 pm 
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4x4kayak2112 wrote:
Atthehelm wrote:
WHITE the civilian wrote:
Hey guys, thanks for the kind words. I'm really into MIG, it's like cheating compared to some 7018 rods from the year 400 B.C. Once I get set up in the garage at the new apartment Im moving into soon, I'll mock up a cardboard bumper and then see if I can get my hands on some 1/4" plate. Thought about using 3/8" at first then realized I'm not driving an F350.. :lol:

What thickness is your KK bumper Helm?

3/16" for the 'skin' and 1/4" for the mounts.. Pretty much the norm for bumpers.

1/4" for everything on your bumper will make it pretty heavy..

The ones i build too are also 3/16" skin with 1/4" mounts and winch plate.


For the life of me I can't see 3/16 being strong enough to take a beating..

Is that what the ARB bumper is made out of?
I planned on making a hybrid stubby bumper with prerunner flares out to the sides.

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OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


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 Post subject: Re: Welding School / build thread.
PostPosted: Sat Mar 28, 2015 1:04 am 
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ARB bumpers thinner than 3/16.. But they use high speed steel. some companies even use 1/8" (11 gauge) or 10 gauge.

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 Post subject: Re: Welding School / build thread.
PostPosted: Sat Mar 28, 2015 1:35 am 
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Well you learn something new everyday, can't believe a thin bumper is worth spending $1,300 on. Can't wait to purchase my own MIG and plasma cutter.

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OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


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 Post subject: Re: Welding School / build thread.
PostPosted: Sat Mar 28, 2015 3:10 pm 
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Like ATH I used 3/16ths...If I remember right the weight difference from 3/16th to 1/4 was over 50lbs...

The difference from 3/16 to 1/4 for my rock rails was almost 75lbs too haha. These are definitely beefy enough haha.

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 Post subject: Re: Welding School / build thread.
PostPosted: Sat Mar 28, 2015 11:08 pm 
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WHITE the civilian wrote:
Well you learn something new everyday, can't believe a thin bumper is worth spending $1,300 on. Can't wait to purchase my own MIG and plasma cutter.

Its not just thin metal, its HSS, so its actually just as strong as a 3/16" bumper without all the weight.

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2002 KJ Limited 3.7, 5.25" lift via coilovers, custom HD rear springs, 32.2" tires on moabs (soon 33s) 4.56/JBA diff, OX lockers front/rear, NP241OR, Parker Fab front/rear bumpers, rock rails and roof rack, Viair OBA.

2006 KJ sport 3.7, 4" Ironman lift, 32" tires, Parker Fab front/rear bumpers and rock rails.


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 Post subject: Re: Welding School / build thread.
PostPosted: Sun Mar 29, 2015 12:26 am 
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4x4kayak2112 wrote:
WHITE the civilian wrote:
Well you learn something new everyday, can't believe a thin bumper is worth spending $1,300 on. Can't wait to purchase my own MIG and plasma cutter.

Its not just thin metal, its HSS, so its actually just as strong as a 3/16" bumper without all the weight.


Hmm, good to know! Now I know how I'll be spending my optional days in school. I'll begin practicing on 1/8 and 3/16 steel this coming week. :P

_________________
OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


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 Post subject: Re: Welding School / build thread.
PostPosted: Sun Mar 29, 2015 12:43 am 
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Watch for warping, it's not fun to get it welded up to watch it cool into a twisted mess. Been there & and learned that lesson quickly.

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08 KK OEM skid plates, JK winch bumper w/ Hella 500s, K&N filter, JKS front discos, black out headlights w/ fogs added, blacked out & euro mod tail lights, Curt Hitch w/ oem wiring, OME Springs, JBA UCA & top plates, Cabin Filter Retro Fit, Custom Fender Mounted Light Mounts w/ Hella 500s, ATH roof bars, rear flush mount LEDs


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 Post subject: Re: Welding School / build thread.
PostPosted: Sun Mar 29, 2015 6:40 am 
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toy4everyseason wrote:
Watch for warping, it's not fun to get it welded up to watch it cool into a twisted mess. Been there & and learned that lesson quickly.


I have a shops metal to play around with 9-6 Monday through Friday, I'll heed your words and practice until I get it right.

_________________
OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


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 Post subject: Re: Welding School / build thread.
PostPosted: Mon Mar 30, 2015 9:00 pm 
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Went in today and left feeling pretty good about the 1G I did with F.C.A.W, 285 - 23.5V:

Image

_________________
OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


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 Post subject: Re: Welding School / build thread.
PostPosted: Tue Mar 31, 2015 7:50 pm 
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I have very little welding training, mostly self taught, but those are looking pretty good to me. Mig is pretty awesome. I really need to ditch my flux core 110 ac buzz box & get a nice mig machine.

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 Post subject: Re: Welding School / build thread.
PostPosted: Wed Apr 01, 2015 5:42 pm 
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toy4everyseason wrote:
I have very little welding training, mostly self taught, but those are looking pretty good to me. Mig is pretty awesome. I really need to ditch my flux core 110 ac buzz box & get a nice mig machine.


Hey Toy4, thanks for the compliment :lol:
Anywho.. the machine I use in class is a Lincoln C300: Image

Also, the plasma cutter we use is a Lincoln 625 Tomahawk: Image

Those 110 Buzz Boxes aren't bad at all, limited, but not bad. Other than fabbin up bumpers they can fix nearly anything metal around the house. I'll be getting one in the future.

The Lincoln C300 is about $5,600 a piece plus consumables, metal and gas. I've also never had to stop and let it cool down even after hour upon hour of welding. You get what you pay for I guess :wink:

it'll be a little while until I have something comparable of my own...

_________________
OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


Last edited by WHITE the civilian on Thu Apr 02, 2015 11:57 pm, edited 2 times in total.

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 Post subject: Re: Welding School / build thread.
PostPosted: Wed Apr 01, 2015 5:50 pm 
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I was thrown a little curve ball today and had to use .035 " solid wire for the first time ever. Had to knock out a 1G and 2G groove weld.

First attempt at a 1G (Plate is flat on ground / table ):Image

Then the 2G (Plate is held vertically but weld is horizontal from left to right or R to L ):Image

One things for certain, I prefer .045" flux core...

_________________
OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


Last edited by WHITE the civilian on Thu Apr 02, 2015 3:03 am, edited 1 time in total.

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 Post subject: Re: Welding School / build thread.
PostPosted: Wed Apr 01, 2015 7:32 pm 
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WHITE the civilian wrote:
toy4everyseason wrote:
I have very little welding training, mostly self taught, but those are looking pretty good to me. Mig is pretty awesome. I really need to ditch my flux core 110 ac buzz box & get a nice mig machine.


Hey Toy4, thanks for the compliment :roll:
Anywho.



It really was meant as a compliment but I must have portrayed it incorrectly. I would have been happy with that weld. I wish I had time to go to school but I'm afraid I don't have time with my family and career. Keep up the good work :rockon:

_________________
08 KK OEM skid plates, JK winch bumper w/ Hella 500s, K&N filter, JKS front discos, black out headlights w/ fogs added, blacked out & euro mod tail lights, Curt Hitch w/ oem wiring, OME Springs, JBA UCA & top plates, Cabin Filter Retro Fit, Custom Fender Mounted Light Mounts w/ Hella 500s, ATH roof bars, rear flush mount LEDs


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 Post subject: Re: Welding School / build thread.
PostPosted: Thu Apr 02, 2015 7:44 pm 
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Today in class was our mid terms for our current mod we are in, knocked out a few groove welds 2G and 3G.
But instead of sharing those boring groove welds with you I'll show my rock rail project!
Before you get excited, know that I'm not building from scratch but fixing a bend from a car accident many months ago.

The first thing to do was to get it off the vehicle.

Image

Image

An instructor showed me how to change out heads on the acetylene torch so we did that and started preheating the bend area with the hopes of bending it back.

Image

My turn: Image

Spoiler alert - it didn't bend despite being translucent at a certain point. Image

So, We figured it had to be cut and have a new 2x2" section put in. I went out to the other rock rail and measured, 63" in length. The original rail is about 3/16" while the new section is 1/4" wall thickness. Used the grinder to bevel the edges. The top piece is the bend and under that is the 1/4" piece I cut to fit. Image

Rough bevels but I'll finish them up next week when I tack it all together.
Image

_________________
OME 2.75" lift. JBA UCA's.
Flowmaster super 44.
BoulderBars. Home built stubby.

31X10.5 Duratracs
Yukon / Motive Gear 4.10's

Aussie Locker. Safari Snorkel.
ARB Diff Guard
Soft 8 - X7 - 4" BS


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 Post subject: Re: Welding School / build thread.
PostPosted: Thu Apr 02, 2015 8:40 pm 
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Do you guys get to load test your welds? It would be a fun contest to find out who in the class can make the strongest weld.

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08 KK OEM skid plates, JK winch bumper w/ Hella 500s, K&N filter, JKS front discos, black out headlights w/ fogs added, blacked out & euro mod tail lights, Curt Hitch w/ oem wiring, OME Springs, JBA UCA & top plates, Cabin Filter Retro Fit, Custom Fender Mounted Light Mounts w/ Hella 500s, ATH roof bars, rear flush mount LEDs


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 Post subject: Re: Welding School / build thread.
PostPosted: Thu Apr 02, 2015 9:27 pm 
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[quote="WHITE the civilian"]
Image

:shock: :shock: :shock: :shock:

THAT is bent haha

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