The fabrication thread.

[GSXRJJordan]

Originally Posted by duffman1278

So I would assume because of the higher heat with using dual shielded, that it would not be good to use on sheet metal for cars?

LOL penetration is virtually a non-issue with sheet metal...

[Jonnie Fraz]

Originally Posted by GSXRJJordan

LOL penetration is virtually a non-issue with sheet metal...

LOL..."sheet metal" is a relative term. My laser cutter calls 1/4" sheet metal.

For like body sheet metal I have heard real good things about silicon bronze wire for bodywork since it is soft and easier to grind, and it has great anti-corrosion charactoristics.

[atutt]

Originally Posted by Jonnie Fraz

It is not a matter of the machine being inferior to itself, it is a matter of using the right filler for the job.
I only use dual sheild on very heavy/ super high strength applications.
Atutt is right in the fact that the welds are super high penatration, and look awesome after you clean off the slag...but since they are so high heat and penatration it has a tendency to cause a lot of heat distortion, so dual sheild is not for all applacations in my opinion.

Correct. I used it a lot in the construction indusrty. I've used for cranes and heavy equipment machinery... Like this gian ass (like 20ft) plow blade. It was almost 4'' thick in some spots.

Originally Posted by Jonnie Fraz

LOL..."sheet metal" is a relative term. My laser cutter calls 1/4" sheet metal.

For like body sheet metal I have heard real good things about silicon bronze wire for bodywork since it is soft and easier to grind, and it has great anti-corrosion charactoristics.

Up here anything over 3/16'' is technically "plate".

I only mentioned the dual shield flux core to open up some closed minds about flux core.

[Jonnie Fraz]

Originally Posted by atutt

I only mentioned the dual shield flux core to open up some closed minds about flux core.

Sweet...Welding is like driving from California to New York...there are a thousand different ways to do it...it is just finding a way that you like to go.

Here is a little somthing I did today...

I have been working on re-designing my fender braces...I like these.

[duffman1278]

Originally Posted by GSXRJJordan

LOL penetration is virtually a non-issue with sheet metal...

I'm not talking so much about the penetration but more about burning a hole through it because of the higher heat.

I found out yesterday though that I have a 220V plug in my house that I can get access to in my backyard lol So I might look into a TIG welder eventually because I don't think you can MIG weld or flux core with thin aluminum pieces such as intercooler piping.

[Jonnie Fraz]

Originally Posted by duffman1278

I found out yesterday though that I have a 220V plug in my house that I can get access to in my backyard lol So I might look into a TIG welder eventually because I don't think you can MIG weld or flux core with thin aluminum pieces such as intercooler piping.

Correct...about the thinest aluminum MIG welding I have had luck with is 1/16"...not saying it is not possable, just high skill factor.
Now on to the TIG...Look at machines that are AC/DC and have HF start. You will be looking at machines $1500.00 and up.

[khilgers]

this is nothing even close to what you guys are making, but it's a start.

I made a skid plate yesterday. Sheet aluminum .080" 2'x3' cost $9 at the local steel supply.

It's nothing fancy, but it does the job and only cost about $14 to make.

[GSXRJJordan]

Originally Posted by khilgers

this is nothing even close to what you guys are making, but it's a start.

I made a skid plate yesterday. Sheet aluminum .080" 2'x3' cost $9 at the local steel supply.

It's nothing fancy, but it does the job and only cost about $14 to make.

That looks awesome for $15! I've never been a huge fan of skid plates (just makes the bottom even lower, meaning you'll scrape even more), but .080" seems like it'll be sturdy enough to take a beating, and what's a 10th of an inch in overall clearance?

I like!

[khilgers]

Thanks dude. The bend was a little tricky seeing is I don't have the proper equipment. Being a carpenter I made a jig that attached to my workbench, took the heatgun, and away I went. Good way to kill an afternoon when we finally reached 60 degrees here in MN.

[yabeet]

Hey guys I put my S14 SR in my S13 using a dohc tb cable.
I have tried bending the stock bracket slightly since no matter how much I adjust it, after pressing the gas pedal it wont go all the way back down and stays revving a bit.

Does anyone have any pics of a custom made tb cable bracket before I make a crazy looking one that is overkill? Searching was too broad... thanks!

[GSXRJJordan]

Originally Posted by yabeet

Hey guys I put my S14 SR in my S13 using a dohc tb cable.
I have tried bending the stock bracket slightly since no matter how much I adjust it, after pressing the gas pedal it wont go all the way back down and stays revving a bit.

Does anyone have any pics of a custom made tb cable bracket before I make a crazy looking one that is overkill? Searching was too broad... thanks!

No custom bracket needed, just adjust the cable free-play, using the two nuts (one on either side of the bracket).

[Rapier46]

Originally Posted by Jonnie Fraz

Sweet...Welding is like driving from California to New York...there are a thousand different ways to do it...it is just finding a way that you like to go.

Here is a little somthing I did today...

I have been working on re-designing my fender braces...I like these.

Do these do alot? I am seeing them more and more. Why exaclty to people have them? A substitute to stitch welding? I guess any extra strength helps, but i dont see a mjaor benefit of fender braces.

[GSXRJJordan]

Originally Posted by Rapier46

Do these do alot? I am seeing them more and more. Why exaclty to people have them? A substitute to stitch welding? I guess any extra strength helps, but i dont see a mjaor benefit of fender braces.

Much stiffer than stitch welding. Only problem is, by stiffening the front even more, you induce even more understeer (my car already understeers, even with just stock sways). That's the only reason I haven't done it yet.

[420sx]

ls1 y pipe and exhaust for my 240









now it is all tigged and tucked in. feels good to be gangsta.

now its sway bar mod/fab time!

[yabeet]

Originally Posted by GSXRJJordan

No custom bracket needed, just adjust the cable free-play, using the two nuts (one on either side of the bracket).

I have the nuts all the way back on the tb cable, it is almost there. If I push down on the tb bracket it will idle normally but once I put my foot on the gas and let off; the dowel [the one to prevent the tb plate going the other way] is 1-2mm from touching the stopper.
Doesnt seem like a common problem so I will just fab one up I guess.

[duffman1278]

Got to TIG weld some 4130 Chromoly tubes for a chasis at school, thats for a project. It was kinda scary at first but I got the hang of it. I'll try to remember my camera tomorrow and post up pics here.

I just really struggled with really tight spaces of the tubing.

[onepuff]

Took the plunge and started cutting.




Got the templates made.




Gonna cut up some sheet tomorrow.

Jeff i don't know how the hell you did it with the motor in.

[GSXRJJordan]

Originally Posted by yabeet

I have the nuts all the way back on the tb cable, it is almost there. If I push down on the tb bracket it will idle normally but once I put my foot on the gas and let off; the dowel [the one to prevent the tb plate going the other way] is 1-2mm from touching the stopper.
Doesnt seem like a common problem so I will just fab one up I guess.

Doesn't sound like you bent the bracket as far forward as I bent mine lol.

Originally Posted by duffman1278

Got to TIG weld some 4130 Chromoly tubes for a chasis at school, thats for a project. It was kinda scary at first but I got the hang of it. I'll try to remember my camera tomorrow and post up pics here.

I just really struggled with really tight spaces of the tubing.

Yeah man, post some pics!!

Originally Posted by onepuff

Took the plunge and started cutting.
...
Jeff i don't know how the hell you did it with the motor in.

Haha, I didn't cut that far back on the driver's side, and I did a lot of cutting from the "wheel well" side, not the engine side (fender off). Cutting is the easy part lol, but your templates look really good!

[discosteak]

i dont really have an pics of stuff i fabbed but heres some welding i did. im an unemployed aerospace welder

[duffman1278]

I'm not gonna lie but those welds look, STUPIDLY AMAZING!!!

That is some clean welding for sure!

[onepuff]

Originally Posted by GSXRJJordan

Haha, I didn't cut that far back on the driver's side, and I did a lot of cutting from the "wheel well" side, not the engine side (fender off). Cutting is the easy part lol, but your templates look really good!

Thanks. I had to cut that shit out on the driver's side. It was all rusted out pretty bad. Had to go down past the frame rail. I was pretty amazed at how well the HF spot weld drill bit worked too.

[discosteak]

Originally Posted by duffman1278

I'm not gonna lie but those welds look, STUPIDLY AMAZING!!!

That is some clean welding for sure!

haha thanks

[nieko]

orbital????

[discosteak]

no it was done by hand. IMO orbital still looks better/tighter. and i dont think ive ever seen an orbital this small lol.

[discosteak]

some other stuff ive done
SR20 Corolla











made a custom trans tunnel, cage and handbrake



My car

[rican_nick]

Originally Posted by discosteak

no it was done by hand. IMO orbital still looks better/tighter. and i dont think ive ever seen an orbital this small lol. http://c1.ac-images.myspacecdn.com/i...2301e74a60.jpg

wow thats bad ass good job man.

[discosteak]

Originally Posted by rican_nick

wow thats bad ass good job man.

thank you
msg length

[GSXRJJordan]

Originally Posted by onepuff

... I was pretty amazed at how well the HF spot weld drill bit worked too.

Hell yeah! I'm on my 2nd one (they wear out), but it rocks! Esp with a corded, high speed drill, and not my cheap battery one.

Originally Posted by discosteak

haha thanks

Dude, those welds are ridiculous for being done by hand... assuming the tubing is clamped down, how much do you do at a time? 180*? I can't see any start/stop pools... shit's rad.

Oh, and the crossbar on your cage (roof to floor) looks like it's offset from the main hoop? Whats that?

[discosteak]

Originally Posted by GSXRJJordan

Dude, those welds are ridiculous for being done by hand... assuming the tubing is clamped down, how much do you do at a time? 180*? I can't see any start/stop pools... shit's rad.

Oh, and the crossbar on your cage (roof to floor) looks like it's offset from the main hoop? Whats that?

tube was put in a vice i started at the bottom and worked my way all the way around , no stops. (after the initial tack weld)

harness bar is offset not the diagonal, I'm 6'1 260lbs just moved it back for a little extra room

heres a pic you can see the tubes arent actually straight


and you can see the only stop on the lower weld in this pic right side

[duffman1278]

Here's some of the welding I got done today from school.

We got the chasis already made from another team, but they're kart was for all motor. Ours is going to be electric/fuel so we have to alter the chasis for our setup.

The pics shows the battery trays we made and welded up. We'll be welding up the supports for the motor tomorrow hopefully.

I know the welds don't look that nice, but hey I havn't been welding for years lol I'm still noobish And yes there is some oxidation on the welds, I asked one of the welding instructors why that occurs, he said it's probably due to the moisture in the air. I'm running argon, enough.