Welder Cord Rack

Rch · Feb 1, 2003

An early project with my new Lincoln MIG 200 welder. The cord rack has to "lean forward" so the 2 hinged bins on top of the welder will open. You can see the hinges on top of the welder. I bolted it to the welders handle. It didn't seem like a good idea to weld on the welder.

Spencer · Feb 1, 2003

I couldn't view the attachment. /forums/images/graemlins/confused.gif

Rch · Feb 1, 2003

Spence, I think I fixed it.

Rch · Feb 1, 2003

Number 2

jimgerken · Feb 4, 2003

Looks good, I have been needing something similar, Thanks, you've given me some good ideas here. A little positive input for you, on the welding. In the future, on important high-stress weldments, try to avoid welding across the flat tab where it exits the main frame section. If the cord holder was a highly stressed piece, that weld area would be a natural place for the crack to start. A lot of times, I remind myself that "less is more" when welding. Using just what weld is needed, where its needed, minimizes the stresses and shrinkage distortion. On the other hand, sometimes its less critical, more fun, and too easy to just poor it on. /forums/images/graemlins/grin.gif

Rch · Feb 4, 2003

Jim, good point. As I'm plowing through the "Welder Guide" from Lincoln Electric there is a big section on that very topic. RCH /forums/images/graemlins/laugh.gif /forums/images/graemlins/laugh.gif

Spencer · Feb 4, 2003

</font><font color="blue" class="small">( In the future, on important high-stress weldments, try to avoid welding across the flat tab where it exits the main frame section. )</font>

Jim, Can you try to explain that in a different way? /forums/images/graemlins/confused.gif
I'm not even close to understanding what you are saying. /forums/images/graemlins/frown.gif

jimgerken · Feb 5, 2003

Yea, as I read my post I wondered if it was understand-able. It is easier to show in pictures than to write, but here goes another attempt. If an element of a frame is subject to bending, you would want to avoid welding across the element. Imagine as you weld you are embrittling the metal, and adding a stress riser, and changing the cross sectional area, all at once. Now put that weld section in tension and you will see it naturally crack right where you welded across. Like, if you took a pc of 1/4" by 2" flat iron two feet long, and screwed down through it into your workbench, leaving a foot hanging over. Now hang a load on it and it will bend predictably. Do a second one and before loading it weld across the 2" width right where it is setting on the table edge. Now when you load it it will act differently and may crack right next to the weld, in the base metal or in the joint of the weld and the base. I guess to add any more technical detail than this I will have to resort to my welding handbook. Maybe I better go dig it up.

Anonymous Poster · Feb 6, 2003

RCH: Jim is mentioning the very thing that I noticed when I viewed your well thought out cord rack. What he is talking about is LEAVING THE ENDS OPEN for the stress to work it's way out. You lay the piece of flat stock on the frame and weld along the SIDES OF THE FLAT STOCK ONLY.....not across the end and not where it meets the frame. If you weld across where the flat stock meets the frame and weld all around, you may as well not have the square area at all, just butt the flat on the edge of the frame and weld it.......it'll hold just as much. This is kind of the same thing as welding across a channel iron trailer frame.....it's not a good idea.....stay longitudinal if possible. /forums/images/graemlins/tongue.gif

Rch · Feb 6, 2003

CJDave, I see your point. Thanks. Those beads were going down so nice I just couldn't stop /forums/images/graemlins/smirk.gif /forums/images/graemlins/smirk.gif