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Bending Brake Welding Question

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bill_dom(at)yahoo.com
Guest

Posted: Sat Apr 15, 2006 5:03 am Post subject: Bending Brake Welding Question

I bought Zenith bending brake plans and I have all the

parts ready for welding. The end plates are 1/8 inch

thick and need to be welded to the end of 4 x 4

angular that are 1/4 of an inch thick. Both material

are steel. My questions are:



- The manual recommends arc welding to avoid heat

distortion. Is there any way that can be gas welded

with no heat distortion?



- If I gas weld, should I use a tip for 1/8 or a tip

for 1/4



- What would be the most economical arc welder for

this job? The cheapest ones welds up to 3/16 in a

single pass, what does this mean? Will it weld thicker

by multi passing?



- Any other recommendation.



I have no welding experience but I want to learn and I

have enough scrap metal to practice. I also have

Richard Finchs Welder Handbook.



Thanks



William Dominguez

Plansbuilt Zodiac 601XL

Working on bending brake

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jean-paul.roy4(at)tlb.sym
Guest

Posted: Sat Apr 15, 2006 5:40 am Post subject: Bending Brake Welding Question

Hi William. Would you have a link to direct me for buying these plans.



Thanks



Jean-Paul

do not archive

---

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d.goddard(at)ns.sympatico
Guest

Posted: Sat Apr 15, 2006 5:46 am Post subject: Bending Brake Welding Question

---

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bill_dom(at)yahoo.com
Guest

Posted: Sat Apr 15, 2006 6:16 am Post subject: Bending Brake Welding Question

I ordered them by phone however, it is the same design

as this one:



http://www.ch601.org/tools/sm_brake_1.pdf

http://www.ch601.org/tools/sm_brake_2.pdf



Zenith plans are more detailed and for 20 bucks it is

worth it.



William Dominguez

Plansbuilt Zodiac 601XL

Working on bending brake



--- Jean-Paul Roy <jean-paul.roy4(at)tlb.sympatico.ca>

wrote:



[quote] 

 <jean-paul.roy4(at)tlb.sympatico.ca>

 

 Hi William. Would you have a link to direct me for

 buying these plans.

 

 Thanks

 

 Jean-Paul

 do not archive

 ---

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naumuk(at)alltel.net
Guest

Posted: Sat Apr 15, 2006 7:02 am Post subject: Bending Brake Welding Question

Bill-

    I've used a Lincoln stick welder of one model or another for over 35 

years. Just what I'm familiar with, I suppose. Best if you have access to 

240V.  You can get a dual steel/aluminum model for around $300 US if you 

watch for the sales. Problem is, gold is cheaper than the aluminum rods.

    When I was a teenager, I welded the roll cage for a stock car where the 

driver caught a  T bone right at him. The well case bent as much as 6", but 

the welds never broke. I had maybe 75 hours experience with the welder at 

that point. Suppose you could say you don't have to worry whether the welder 

was capable. Not me, the machine!

                                                                             

                                                                             

         Bill

                                                                do not 

archive

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larry(at)macsmachine.com
Guest

Posted: Sat Apr 15, 2006 7:02 am Post subject: Bending Brake Welding Question

William,

The larger tip would be the better tool for the material as it will 

spread the heat better and allow

you to focus on the weld more easily if you decide to gas weld.  Trying 

to weld with a lesser tip would

require you slow down and spend too much time getting the metal to a 

puddle for welding.  Arc welding

is so fast that an arc of short segments can be made with very little or 

no distortion.  Study the shrinkage

that causes distortion and you'll be able to compensate for it.



Welders are best described by their amperage, duty cycle and capacity 

for AC or DC.  A 125 amp

welder capable of AC or DC and able to switch select straight or reverse 

polarity should be a minimum

requirement.  You should find these at Harbor Freight for less than 

$250. Even a used welder can be a good buy.

Ask for a Miller plastic slide guide that describes amp settings, 

polarity and rod size for

most welding jobs.  It will get you on centerline faster than a book. Do 

study Richards book though, because it is an excellent

reference for aircraft and regular welding.

Good luck,



Larry McFarland

do not archive

William Dominguez wrote:



 	  Quote: 	
		  



I bought Zenith bending brake plans and I have all the

parts ready for welding. The end plates are 1/8 inch

thick and need to be welded to the end of 4 x 4

angular that are 1/4 of an inch thick. Both material

are steel. My questions are:



- The manual recommends arc welding to avoid heat

distortion. Is there any way that can be gas welded

with no heat distortion?



- If I gas weld, should I use a tip for 1/8 or a tip

for 1/4



- What would be the most economical arc welder for

this job? The cheapest ones welds up to 3/16 in a

single pass, what does this mean? Will it weld thicker

by multi passing?



- Any other recommendation.



I have no welding experience but I want to learn and I

have enough scrap metal to practice. I also have

Richard Finchs Welder Handbook.



Thanks



William Dominguez

Plansbuilt Zodiac 601XL

Working on bending brake

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TH-SR

Joined: 13 Jan 2006
Posts: 22
Location: WI

Posted: Sat Apr 15, 2006 7:08 am Post subject: Bending Brake Welding Question

Attn: Mark Townsend



I'm sure many posts to the list, from those that have viewed the Homebuilt

Help Video, are looking for plans to the bender you have constructed (as

shown in the video). Are yours plans available to us scratch-builders?



Thanks,

Todd Henning



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_________________
Todd
CH701

p.mulwitz(at)worldnet.att
Guest

Posted: Sat Apr 15, 2006 8:27 am Post subject: Bending Brake Welding Question

I think arc welding in all forms is potentially much more dangerous 

than gas welding.  The energy developed in the arc can produce all 

sorts of damage to humans from sunburn to radiation poisoning to 

blindness.  Gas welding has none of these risks associated with it - 

but you certainly can get your fingers burned.



I learned gas welding from a book many years ago and have used it 

from time to time.  I don't think there are any size limits to the 

process - just limits brought on by the size of the acetylene tank 

you have.  There are also no real limits in the processes you can do 

including welding, brazing, cutting, and other useful things.



To prevent warping in heavy steel like you described, all you really 

need to do is tack weld the corners and perhaps a couple of places in 

the middle of the joint and then fill in the bead for the length of 

the joint.  The tack welds will hold the pieces in place and prevent bending.



Good luck,



Paul

XL wings



 	  Quote: 	
		  - The manual recommends arc welding to avoid heat

distortion. Is there any way that can be gas welded

with no heat distortion?

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zodierocket(at)hsfx.ca
Guest

Posted: Sat Apr 15, 2006 2:19 pm Post subject: Bending Brake Welding Question

Hi Todd and others, I designed my brake from the ground up for the sole

use of building the Zodiac and Sky Jeep in mind, using simple materials

and a cheap cost. In that, the brake works like a charm, but my hand

scribbling to work out the math necessary to get the brake to work well

is a mess, I did not even use a ruler. I do not own AutoCAD software nor

do I know how to use such software, I am just a plane builder. So

several months ago a fellow visiting my shop asked to take measured

drawings of the brake and has offered to send me the finished drawings

that were mentioned in the DVD from Homebuilthelp.com. To date I still

have not seen those drawings, he is still promising them to me and he is

a trustworthy type of person, after all he is building a Zenith!

Therefore, as soon as I have them (and he will also get this post) I

will add them to the website. I hope that it will be sooner then later!



Mark Townsend  Alma, Ontario

Zodiac 601XL C-GOXL, CH701 just started

www.ch601.org / www.ch701.com / www.Osprey2.com



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