Welding has started !!! :D

Gave my cousins partner a hand to bring his 250amp Mig welder to my place this afternoon, boy does he make this welding stuff look easy, and I guess having some welding grunt certainly helps too.

We tacked all the foot plates on to the legs this afternoon and run a couple of full welds around the feet just to get our setup right.
We should be giving the table builds a good old nudge this coming Saturday, with all the prep work being already done, so we are hoping for some serious progress.
I will post some progress photos as it happens.

Cheers
Tony.

Tony, if your friend did full welds around the feet you are going to have your hands full holding him back from overwelding everything else! :)

Must say Tony, your coming along nicely too !!
Good luck on your build ;)

Hey Tony, nice work, just jumped onto the forum tonight, cold you pm me what supplier details you have? i am super keen to build a larger table myself down in sydney

Now there are no looking back... Way to to Tony!

Thanks Guys,

I will be happy if I can build ours to the high standards of workmanship that most of you have set ;) trying my best !!
Thought I would post a couple of pics of the table legs / feet already to go for Saturday. Going to be a big day!! but really looking forward to it. Bring it On !!

Start your engines :D

http://i142.photobucket.com/albums/r...k/IMG_0374.jpg

Nice Legs !! :rolleyes:

http://i142.photobucket.com/albums/r...k/IMG_0375.jpg

First full weld to one leg!! All under control Gerald :p

http://i142.photobucket.com/albums/r...IMG_0376-1.jpg

Tony, just as a guide, where a square box section joins to anything, only weld 2 of the 4 faces......that is enough for us.

Thanks for your advice Gerald, we will be fully welding everything other than where we need to follow the strict welding paterns on the gantrys etc. As per your earlier advice we will be taking the welding all very slowly and only doing one side and then the opposite side and then moving between legs until they are all done.

Spent the whole day in the garage again today creating space and planning the build for both tables, I also had a look at the best way of clamping the legs to the beams to keep everything true and square.
I found that the flat side of the PFC's all have the slightest bow in them, so I have decided to work off the edge of the flanges which appear to be pretty good.
I clamp a piece of box section to the beam and then clamp the legs to that after using a builders square to keep things right. I then placed my rails in position which fitted perfectly. Once everything was in place I then checked the frame for square and all was absolutely spot on. Lets hope it all stays that way once we start to spot and then weld. :D

Here are a couple of photos of how I plan to set the frames up.

http://i142.photobucket.com/albums/r...k/IMG_0377.jpg

http://i142.photobucket.com/albums/r...k/IMG_0378.jpg

Cheers
Tony.

Tony, if you full weld those 3 legs per beam (12 welds), my estimate is that you will bow that beam by at least 2-3mm. (The middle leg causing the most grief).

Gerald,

would that still be the case even if everything (complete table) is all tacked in place first, including all the legs, lower rails and all table bracing as well as the Y axis PFC supports ?? before any full welds are done. when I say full welds I mean one side of each piece, then go to the furthest away one and do the same again until all are done. Will this still cause problems Gerald?
In which direction will it bow Gerald?

Cheers
Tony.

Tony - clamp a straight piece of steel like so (a bit higher up actually !)
It might help hold everything together.

Regards
Ross
Attachment 9153

Tony, your expericenced friend that is helping you with the welding will give you a very good idea of where it will bow. All that I am pointing out is that full welds, versus 50% welds, will take twice as long, cause double the distortion and give you zero improvement in the stiffness of the table.

Ross, you don't need six leg, my table is 4.4m long & I only have 2 legs on each beam.
Sometime less is more. ;)

Gidday Ken (and Tony)

The beam I proposed is just a temporary brace clamped up with F clamps and then removed after welding. Hope this is clear now.

Regards
Ross

Very clear, actually I mix up tony & ross identity.... had one drink to many last night... :o

Ross,

No probs Ross, I understood where you were coming from.
will post some photos later, I am very impressed with what we achieved today. Got heaps done, and no distortion.
We have checked the table for acuracy, straight, parallel, square in every which direction and to be honest I am over the moon with the acuracy we have achieved.

Cheers
Tony.

I am very happy that you got it right Tony!

Todays Update.

Thanks Gerald,

We did take your advice, and our welder also said he was only going to weld either side of the legs to the main beams so all good:D
We did however fully weld all the other joints, other than under the long cut mitres which we could not get too.
We managed to get one table almost completely finished with the two side frames finished for the second table So probably another short day left to completely finish both tables:)

Anyway on with the obligatory photographs.

Welded all the foot plates first x 12

http://i142.photobucket.com/albums/r...k/DSC_2744.jpg

The master welder at work welding the inside seams at the end of the main X beams.

http://i142.photobucket.com/albums/r...k/DSC_2739.jpg

End of the beams all complete welded inside and out.

http://i142.photobucket.com/albums/r...k/DSC_2741.jpg

Setting up for the first of four of the main X axis side frames.

http://i142.photobucket.com/albums/r...k/DSC_2745.jpg

We then let the welder loose on the first of the main X axis side frames.

http://i142.photobucket.com/albums/r...k/DSC_2748.jpg

Here is how the joints / welds ended up, not much cleaning up too do:D

http://i142.photobucket.com/albums/r...k/DSC_2752.jpg

Two main X axis frames down!! bring it on!!

http://i142.photobucket.com/albums/r...k/DSC_2755.jpg

Now onto the first of the main X axis side frames for the second table.

http://i142.photobucket.com/albums/r...k/DSC_2756.jpg

With all the side frames done and finished we tried a different tact on how to weld the two side frames together trying to reduce the amount of turning of the table whilst maintaing accuracy of the table. It took a little time to get it the way we wanted it, but it paid off in the end :D

http://i142.photobucket.com/albums/r...k/DSC_2757.jpg

One happy chappie in the photograph being me, the other happy chappie being skippy taking the photograph, and one burnt out welder fellow standing out of sight. I think we might have worked him too hard :D

http://i142.photobucket.com/albums/r...k/DSC_2759.jpg

First table not quite finished but very close with the largest part of the second table done also which you can see standing up in the back of the garage. Another day should see them both done and dusted.

http://i142.photobucket.com/albums/r...k/DSC_2761.jpg

Cheers
Tony.

Well done it looks like a production run..:D

You are getting there, keep it up!

Hi All,

Done a little bit more today, setting up the main X rails on the PFC's to the first table. They are now all drilled and tapped as per the drawings and notes.
All worked out really well and was very easy to setup, and to get the rails in position tightning the appropriate bolts whilst using the blocks and string line method to straighten the rails.

X rail all drilled with the PFC drilled and tapped.

http://i142.photobucket.com/albums/r...k/IMG_0384.jpg

Block and string line setup worked well in straightening the rail with a friendly tap here and there and the tightning of the bolt to hold it in place.

http://i142.photobucket.com/albums/r...k/IMG_0383.jpg

all the bolts in place and one nice and straight X rail :D

http://i142.photobucket.com/albums/r...k/IMG_0382.jpg

I used this aluminium box section with a couple of small angles pop riveted to the underside at each end to maintain the set distance between my X axis rails, again all worked well.

http://i142.photobucket.com/albums/r...k/IMG_0381.jpg

Cheers
Tony.

Hi Tony

I expected nothing less from you, very tidy job indeed and amazing speed of progress.

The smile on your face says it all, a happy bloke passing a significant mile stone.
Bet you slept well over the Easter break as a thousand squats are the best sleeping medication a man can get.

Regards
Ross

Hi All,

Thanks for the kind words Ross, and yes I did sleep well!!last weekend, and will probably sleep even better tonight when I eventually get to bed and not doing Mechmate stuff :D
We managed to completely finish the first table (Skippy's) today and started sussing out the Y gantry and the Y car parts, which I think we have now got our heads around :eek:
we also got all the welding done on my table today other than the Y support channels which will be done next weekend, along with the Y gantry's and hopefully the Y cars for both tables, then the real fun can start.

Skippys table all ready for the y gantry and car to be done now!!

http://i142.photobucket.com/albums/r...k/IMG_0409.jpg

My table all welded other than the Y support channels.

http://i142.photobucket.com/albums/r...k/IMG_0410.jpg

Not a lot of room left in my garage / workshop with two tables in it :eek: but enough room to get the job done!!

http://i142.photobucket.com/albums/r...k/IMG_0411.jpg

My MechMate coming into good use already at this early stage of the build :p

http://i142.photobucket.com/albums/r...k/DSC_2778.jpg

Cheers
Tony.

One ALL ROUNDER machine..:D

Kobus the uses for MM is incredible!! I cannot wait!!
I had a bit of a rest day today as it was too hot working in the garage, I did manage to complete the table though, welding all the y axis support channels to the table, its amazing the difference it makes to the qaulity of ones welds having some welding grunt on tap ;)
I guess I am getting to that stage of the builds where I need to get in the right mind set for the cutting and grinding of all the rails:eek:

http://i142.photobucket.com/albums/r...k/IMG_0413.jpg

Starting to get their now and I hope we can maintain a good steady build speed.

Cheers
Tony.

Enough of all the tables...Show us that cruiser...:D

Tony,
I would suggest to look at Cam & G code at this stage, I regret not devoting enough effort in this depatment, I'm presently stuck with learning the soft ware... can't proceed to make anything useful now...

Don't worry Ken...I had finished my MM and then only started to look for a suitable CAM program. Looked at many, but in the end Vectric Cut2D got me going in 5 minutes....it is really that easy to learn as this software follows a logical flow.

Tables look great! Aussies drink Corona? :confused:

Kobus,

I will post a pic or two of the Cruiser when I get a chance :D

Ken,

I have been slowly starting to read up on Cam software and G Code and slowly starting to get an understanding. I agree with Kobus though it appears the Vectric's software is the way to go :)

cncb,

In response to your question Aussies drinking Corona:confused:

I'm a Scossie :D and like lots of nice drinks!!:D

I supplied my local fastner place with a list for all our bolts, screws, nuts and bolts today, hopefully they should all be ready for pickup tomorrow ;)

Cheers
Tony.

Aww man,... i want a corona:(

Gantry in the Making
 

Hi,

Done a little bit of prep work setting up the gantry tonight, making sure it is level, straight, parallel and square.
I used some threaded rods through the gantry rails to bolt the laser cut parts and the rails together nice and tight.
so far so good lets hope it stays that way through the welding process.

I am pretty sure I have everything around the right way and I'm sure you will all let me know differently if it is not ;)

http://i142.photobucket.com/albums/r...k/IMG_0415.jpg

http://i142.photobucket.com/albums/r...k/IMG_0416.jpg

Clamps and straps holding everything in place.

http://i142.photobucket.com/albums/r...k/IMG_0417.jpg

Cheers
Tony.

Superb job Mr Tony:)

Todays Update!!

We worked on the welding of the both gantrys today as our first job.
we used 2 x 2m of M10 threaded rod through the slots in the gantry end brackets which ran inside of each of the gantry tubes with washers and nuts at each end tightening the laser cut parts to the tube ends holding everything nicely together.
With them bolted we also bolted the laser cut parts together with the temp M12 bolts again holding everything firmly in place.
The gantry tubes were also clamped down onto the X axis rails, after much checking and squaring the welding sequence took place.

The same process took place for the second gantry and again I am happy to report all went well, with very little to no propellor twisting taking place.

With the gantry's now out of the way we started on the Y car for the first table. Setup again took some time and went through a few setup and checking processes before the welding sequence took place and it all paid of in the end :D

http://i142.photobucket.com/albums/r...k/DSC_2792.jpg

Ross (surfcnc) dropped in and brought along his little pieces of threaded rod for the car, and Ross I'm happy to report they worked a treat.:D

http://i142.photobucket.com/albums/r...k/DSC_2799.jpg

Clamp City here we come!!:) and let the welding begin!!

http://i142.photobucket.com/albums/r...k/DSC_2801.jpg

http://i142.photobucket.com/albums/r...k/DSC_2796.jpg

Ross, (surfcnc) picking up a few welding tips!!;)

http://i142.photobucket.com/albums/r...k/DSC_2797.jpg

Car welds being cleaned up.

http://i142.photobucket.com/albums/r...k/DSC_2807.jpg

Cars all done and dusted. :D

http://i142.photobucket.com/albums/r...k/IMG_0457.jpg

http://i142.photobucket.com/albums/r...IMG_0458-1.jpg

Couple of photos showing the gantrys and cars all finished.

http://i142.photobucket.com/albums/r...k/DSC_2805.jpg

http://i142.photobucket.com/albums/r...k/DSC_2804.jpg

http://i142.photobucket.com/albums/r...k/IMG_0455.jpg

And lastly and not one of clearest photos, and specialy for kobus, the heavy lump of metal sitting next to its best mate MM!!

http://i142.photobucket.com/albums/r...k/IMG_0456.jpg

Cheers
Tony.

Must be a real pleasure riding this on the LONG OPEN road. enjoy.

Cheers Tony

For those interested, on my mission to see the crack team in action, I got one sandwich, two drinks and enough hints to last me six months.

Tony and Paul's tables are precise by no accident, as they are taking every opportunity to check, then recheck, the parts before they are welded.
CONSIDERABLE thought has also gone into getting a good datum to work from and the accuracy they are getting is in a word - fabulous.

Now when did you say those sandwiches were on again ?

Regards
Ross

Thanks for the detail in this build and all the photos - they are really helping me to get my head around the planning.

I'd appreciate a guess at the time spent welding each table to date. I'm guessing 40+ hours?

Hi Red,

I'm glad the detail and photos in my build thread are of help to others, I know that without the detail and photos that others have posted before me, I would certainly have struggled with my build.
Big thanks really need to go to Gerald for this great machine and for this very informative public forum which once you learn how to read it and work out where to find things properly, it really makes the build so much easier.

With regards to welding time, both tables, both gantrys, and both cars the total setup and welding timeall up is probably in the vicinity of close too 35 -40Hrs.
A lot of cutting preperation and grinding was done prior with several hours being worked to get everything ship shape:D but it all appears to have payed off in the end so we are really happy with the results.

Cheers and good luck
Tony.

Hi All,

Drilled and drilled and drilled and tapped :eek:
The good news is!! thats the largest part of the drilling and tapping done. Fitted the X axis rails to the second table and all the Y axis rails also fitted to both Y gantrys.

http://i142.photobucket.com/albums/r...k/IMG_0502.jpg

I decided to trial drilling a hole and then tapped it into an offcut of the gantry tube which is 3mm thick, I then used my ratchet and socket and screwed the bolt in applying enough pressure, and the bolt held strong with no sign of stripping.

http://i142.photobucket.com/albums/r...k/IMG_0504.jpg

So I decided to not use the steel backing strip. I also reduced the bolt centres on the gantry rails to 150mm centres and will apply spring washers also. Should be more than enough.

http://i142.photobucket.com/albums/r...k/IMG_0505.jpg

Hopefully the rain holds off tomorrow and we might get the tables all prepared and cleaned, and some primer on them to stop all the surface rust that keeps appearing.

Cheers
Tony.

Looking good! Should see some serious dust manufacturing real soon!