Your most recent welding pics

[Gamble97]

Can anyone tell me what size the outlets are for the 2g power steering tank? I have some 3/8" and 1/2" barbs so I'm hoping those are the sizes.

And I'm almost done with the 2g overflow. Can someone measure from the bottom how tall the bracket is? Or if anyone has a pic of their overflow so I know about where to put the holes for the bracket?

 

[Archer Fabrications]

Yeah I'll text You later today i have mine removed

Be home in a few hrs

 

[Gamble97]

Thanks
Also the inlet size on the overflow?

 

[antilag_200]

Gamble,

Here was a power steering resevoir that I was doing for my evo before. I have reason to believe that the 2G resevoir is very similiar. It was -10AN (5/8) for the suction side of the pump, and then on the return side of the pump was -6An (3/8)

On to the pics

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Cutting up some polished tubing

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a picture showing the strainer section, baffles etc etc

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all the pieces to the puzzle

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and generally what it will look like once welded up.

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and final location

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[Archer Fabrications]

1/2" top 3/8 bottom

 

[Devilsfutbol17]

I finally got my welder up on a kart, now I just need to get some more work benches to do the welding on.

I also picked up a chop saw and was able to make my first attempt on pie cuts. I have to make my third o2 housing soon for my TS hx35, so I decided to get some practice so I can hopefully make a good one this time.

I ran a few beads on some other extra pipe to try and get my settings dialed in, then I went to town on the pie cuts. Prior to this, my first and only welding experience was making my own turbo back exhaust on my VR4. Sorry for so many pictures, I don't think I did too bad for how much experience I have.

 

[Archer Fabrications]

You need to purge the stainless. The sugar on the inside is going to hinder flow unless you grind it out, even then it will corode at the welds. Tig is choice for these applications
Pie cuts look good though

Okay i dont get it! Why is aluminum my enemy!? Is it the lack of AC balance i have?

This is fresh aluminum plastic peeled off, brushed with a new ss brush and acetoned. I HATE alum edges, maybe the sheer contaminated it???

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Because then i say okay since the piece is ruined, why not see if it's the machine. I try on the flat part.

And I'll say it turned out much better then the edge but I'm not satisfied at all. Look at all the frost on the edges. I habe no way to control it stupid diversion is only good for steels BOO!

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I dont understand at allllllll

Argon 30cfm

 

[wishihadatalon]

You're bead on plate looks fine. That edge is something else though. Even if it was contaminated, it should turn out better than that. To me, it looks like you didn't have enough heat to get a good fluid puddle. Also, what amperage, tungsten diameter, balled tungsten? I highly doubt its your machine. My square wave 175 has no additional features and I can still get great beads on aluminum butt and fillet joints.

 

[Archer Fabrications]

It's an inverter so tip was sharp 3/32 tungsten 80 amps (plugged in 120v) i know it prob should have been at 125... .100 aluminum.

It looked like the oxide layer was just not going away, so i tried to floor amperage and add filler and no bueno.

I know how to weld aluminum, the plate says that. I just had better luck on my schools synchrowave cause i could control balance.

That edge pissed me off.

 

[Gamble97]

Nothing wrong with the frosted edges. That's the frequency control. It's at 120hz on your machine. That's not bad, I am usually around 140-160hz normally.
Well max is 150hz on the thermal arc. Which will be my only welder soon.
Also I don't acetone or wire brush shit anymore. I haven't had acetone in 6 months.

 

[Archer Fabrications]

How come you dont brush or acetone. Aluminum has an active oxide layer

 

[Gamble97]

How come you dont brush or acetone. Aluminum has an active oxide layer

So what. Just weld it as is. Comes out pretty every time.

 

[Archer Fabrications]

Hummm

 

[Gamble97]

Can you measure the size holes on the power steering bracket? Also where they are and the size of the bracket?
I'm ready to cut out the bottom today and get it welded.

 

[Archer Fabrications]

Yeah give me a min

Holes are 5/16th 2 inch by 1" bracket

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[Gamble97]

Thanks, I'm looking to finish this up tomorrow if you can get me the rest of the info.





Warren,
Why 3 baffles? Any more pics of how you did the bracket on that? I can't picture how that is on there. Looks great though.


Got the bottom of the power steering reseviour on tonight. Awesome fitup = awesome results. Stuff like this I should wire brush or acetone, but I don't have either. At least I don't know where the brush is at. Also used a swivel head torch and standard cup/collet.

 

[wishihadatalon]

So what. Just weld it as is. Comes out pretty every time.

Its not a matter of it coming out. The oxide layer on aluminum melts at a temp much higher than the actual aluminum. On thin stuff, this can be a huge issue

Urban, based on what you're saying, I would say that it is probably a heat issue. Like you said, 80 amps is pretty low for aluminum. For edges, I usually run the wire brush down the edge, but one thing I learned is that not all wire brushes are the same. The shorter handle ones like this

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are much better at removing the oxide layer than one like this

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.

I didn't believe it until I tried it for myself.

 

[Gamble97]

You are correct, but the thin stuff I do is .100. Hardly ever do I have to do anything thinner. Coke cans I wire brush, intercooler piping of .063 I will do If I have a brush. The weld above I did is .063 wall and the top plate is .100. No wire brush at all.

 

[Archer Fabrications]

Its not a matter of it coming out. The oxide layer on aluminum melts at a temp much higher than the actual aluminum. On thin stuff, this can be a huge issue



Urban, based on what you're saying, I would say that it is probably a heat issue. Like you said, 80 amps is pretty low for aluminum. For edges, I usually run the wire brush down the edge, but one thing I learned is that not all wire brushes are the same. The shorter handle ones like this

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are much better at removing the oxide layer than one like this

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.



I didn't believe it until I tried it for myself.

I use a smaller brush then that even

 

[crash89]

Would a wire wheel on an air tool have the same effect? Seems easier to me.. Plus I just bought one along with 3 tubes of welding rod!! 1/16 70s, 1/16 4043, and I forget the number of the one for stainless I bought.

 

[Archer Fabrications]

The wire wheel ised on aluminum must be made of stainless and used for aluminum only to avoid contamination

 

[antilag_200]

Weld of the night ( 1:00 am)

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sch 10
80 amps
3/32 tungsten, Purple E3
#12 gas lens
post flow 8 seconds
pre flow 0.4 secs
0.045 filler rod
one cranky old man, that hate manifolds.

 

[Gamble97]

^Why so many baffles on the power steering can?

Got some new goodies.
2 of the CK flex loc torches. One in a 9 and one in a 17.

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And some more goodies coming!
New foot pedal for my 200ex, since I think my pot failed on it.
Machine torch for the torchmate (no height control though)
Avani fume extractor
And the OEM thermal arc 186 tig torch to see if it works on the tweco 141i.

 

[LovinBoost]

Here's a few pics from a rwd 4g63 oil pan I made today. 3/16" aluminum.

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Now YOU can lay a nice weld! Keep up the good work!

 

[LovinBoost]

Enough overflow tank talk...... here's some more weldporn. According to me because that weld porn guy from Australia dosent think so. What do u guys think it's this "weldporn" worthy??


Here's a bunch from an ecotec header i built yesterday .....

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mike

Simply beautiful!