Learning to weld with a non-aircraft project

On Sat, 27 Mar 2004 03:23:08 GMT, Ernest Christley
wrote:

Veeduber wrote:

As for the original thread, I've found vee-blocks, step-drills and a couple of
throw-away angle-head grinders to be handier than any of the tools mentioned,
other than basic hacksaw & files. Being able to maintain the axis of your
notches is more important than a perfect fit.

Again, Tubemiter program to the rescue. I can't overstress how much my
work improved after I got ahold of this program. It prints a template
for the fitup. Well, part of the template is a couple of lines running
down the side. You first use these lines to get the template wrapped
correctly around the tube, using the bottom one to make sure you're not
wrapping a helix. The lines down the side now run parallel to the tubes
axis. Put a template on both ends, lay the tube on a table and roll a
smaller diameter piece or a yardstick up against it. You'll easily see
when the lines are colinear and be able to maintain the axis.

A point most novice builders fail to appreciate is that the actual amount of
time spent welding is insignificant in relation to the overall project. It
looms large simply because you don't know how to do it or lack confidence in
your skills. The key to success is the same as for any other manual art, be it
typing or car-quals -- you have to practice. The basic principles can be
mastered in about thirty minutes. You'll then need about twenty hours of
practice to produce welds deemed 'safe for flight' (which doesn't mean they'll
be pretty :-)

-R.S.Hoover

I spent 2 hours in the garage today. 1.75hrs in preparation and .25hrs
welding.

I just fishmouthed one end so that it fit properly and then guaged how
the other end should line up by holding a tube in the already
fishmouthed end and marking the opposite end by eye.

Then I went to the grinder and cut the other fishmouth. I always left
it a bit long so that I could adjust the opening one way or the other
if necessary.

Even if the tube ends up having an eighth inch play or slightly more,
it doesn't matter. You will be putting enough filler material on the
weld that the fuselage won't care, and no one will be able to tell
that it wasn't precisely flush. Won't matter in terms of strength and
safety either.

Corky Scott