It seemed like a good idea at the time...

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qwakers
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Re: It seemed like a good idea at the time...

Post by qwakers » Mon Aug 26, 2019 9:10 pm

lots and lots of welding today!  welding off a genny takes a bit of getting used to, so excuse my welds! the generator takes a second or so to throttle up to provide enough current, so the beginnings of each weld are a bit cold, but once you're going all is well..

plus welding upside down is hard
plus i cut a smidge too much out and had to weld a fillet in.
plus i hit thermal protect about 3 times because the welds are huge and the settings are maxed.
plus i don't weld enough to be a artist!

(that enough excuses??? i got a few more!)


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i nabbed a member of staff at about 1pm and got him to run the welder over on the forklift, all was fine and dandy, until i looked at my watch thinking better check the time so i can nab someone to move the genny back inside... only to find its nearly 6pm and everyone is long gone! welding is a huge time suck!

had to call dad and ask him to drop by after putting his horse to bed so he could put the generator away for me  #-o 


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Re: It seemed like a good idea at the time...

Post by warpc0il » Mon Aug 26, 2019 10:53 pm

I had to teach Pauline to weld, with a stick arc welder, for some emergency repairs on a motorcycle recovery trailer, after I broke my hand.

It started as a exercise in swearing, with her coming out with language that I didn't know she knew.

However, after a few hours she wanted to get the angle grinder out to remove her first attempts and have a go-over.

Basically, there's no substitute for practice... :D
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Re: It seemed like a good idea at the time...

Post by qwakers » Wed Aug 28, 2019 8:09 pm

i really got very little done today. the plans where good.

clean up the welds and finish sectioning the rear of the chassis legs and then start on the side panels.


yeah, that didnt happen. weather was awful, all day, and you can weld in the rain, its just not a great idea.

all i got done in the end between torrential downpours is to finish the weld on the offside chassis leg, and section and weld up the neaside leg. which was, i must admit, a much neater job.


the bend
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end of chassis leg...

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notice the pools of water... what a unpleasant day....
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Re: It seemed like a good idea at the time...

Post by qwakers » Sun Sep 01, 2019 7:20 pm

today i finished all of the chassis work and most of the door frame work.

i also cut up the tail lift and nabbed the bottom cross bar to cut as it was the right size.
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chassis work finished...
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door frame..
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roller door runner extensions
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so, whats left?

cut some 12mm ply and fiberglass both sides to infill the box sides
make a door section to fill the gap at the top.
re-lay the floor.
make the panel below the door and the ramp trays so they slide in and out.
finish off the returns beside the door framework
re attach the lighting


still, getting there. and so far, its cost me absolutely nothing bar time and a bit of gas and wire... oh, and a couple of gallons of red for the genny....
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Re: It seemed like a good idea at the time...

Post by qwakers » Wed Sep 04, 2019 7:43 pm

oh dear oh dear, car ate its turbo (amd a full sump of oil) in 40 miles today. in the process it really confused the ecu as all the sensors are covered in oil...

looks like im needing a new turbo then!
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Re: It seemed like a good idea at the time...

Post by ChrisHolmes » Wed Sep 04, 2019 8:13 pm

Oh dear, you cannot weld that one!
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Re: It seemed like a good idea at the time...

Post by qwakers » Wed Sep 04, 2019 8:49 pm

something tells me you're right :D

ive also had a loud 'chuffing' noise from the engine over the last couple of days, i thought it was a cracked exhaust manifold, turns out a injector sealing washer has gone awol..

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just another job to do whilst im in there then....
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Re: It seemed like a good idea at the time...

Post by Lemon » Thu Sep 05, 2019 5:20 am

But just think of the smokescreen you can deploy now!

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Re: It seemed like a good idea at the time...

Post by qwakers » Sun Sep 08, 2019 8:08 pm

ive got the next two weeks off to finish the lorry, seems a bit excessive now, considering its nearly done !

side profiles have now been cut, fiberglassed and gelcoated (grey, cos i had it left over from my garage roof, 4 years ago!)

and glued in:
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i also made a start at refitting the floor. that was more than a little frustrating but is half done, with no pics, soz.

also at the beginning of the week i commissioned a engineering company to fold me up the panel that's going below the door. it needs to be 2.6m long but the sheet only comes in 2m or 2.4 meter lengths, so i had them fold up 2 out of 2m sheet, and i tig welded them together this evening.

i must say, the more i use my hobart tig the more i like it. so neat and tidy, no grinding back, just a bit thirsty on gas and electricity.... considering this is only my 3rd or 4th attempt at tig, im pretty pleased with this....
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go on do your worst, critique this novice welding :D
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Re: It seemed like a good idea at the time...

Post by zippyonline » Sun Sep 08, 2019 8:31 pm

You're noticeably improving on the TIG. I'd say it looks like some porosity on the first picture, but otherwise ok (from a broadly untrained eye/hobbyist). Nice work :)
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Re: It seemed like a good idea at the time...

Post by qwakers » Sun Sep 08, 2019 8:34 pm

yeah the corner part was hard to get the torch height constant. hence the porosity. ill work on that :D
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Re: It seemed like a good idea at the time...

Post by qwakers » Sun Sep 08, 2019 8:35 pm

also worth noting, except where i started and stopped, no filler rod was needed for the entire weld.
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Re: It seemed like a good idea at the time...

Post by qwakers » Mon Sep 09, 2019 8:55 pm

floors in....
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which might turn out to be a mistake, i think ive just made my life far harder than it has to be sorting the ramps... but it was raining so i did what i could in the dry :D

also dismantled and added a section to the door.
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doesn't seem like a lot of stuff done for a 10 hour day.... but sanding fiberglass flat takes forever and i had to put the door together and take it apart again about 10 times....
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Re: It seemed like a good idea at the time...

Post by PeteH » Mon Sep 09, 2019 9:48 pm

zippyonline wrote:
Sun Sep 08, 2019 8:31 pm
looks like some porosity on the first picture
I know what you mean, but I thinks that's just the reverse side of the weld. The reverse side doesn't get gas protection, so it is never as neat as the front side. If you want to blow even more gas into the atmosphere then it's possible to pipe a second supply to the reverse, but that's probably a step too far for a 20 year old Hovis lorry!
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Re: It seemed like a good idea at the time...

Post by qwakers » Mon Sep 09, 2019 9:51 pm

20! .... 20! ....

its 11 :mrgreen:
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Re: It seemed like a good idea at the time...

Post by PeteH » Mon Sep 09, 2019 9:52 pm

Shoot, I tried to guess low! :lol:
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Re: It seemed like a good idea at the time...

Post by qwakers » Tue Sep 10, 2019 11:12 pm

god im tired!

multiple jobs completed today, worked on the lorry all day then home and fitted a new turbo to the laguna...


first thing i did was build the corners of the column up. then i fabricated (fancy word for cut a bit of 2mm sheet up and drilled some holes) a body capping to cover the transition from old body panel to new..
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then i made a couple of infill pieces, and bolted them in, then a couple of coats of paint.
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all is well with the world :D

just the ramps and the electrics to sort now.

then at about 730pm (a full 12hrs after starting my day :D ) i got home to a new turbo for my daily, so i decided to crack on with that.


first off i had to remove the snapped studs in the manifold and used cut off bolts (because that's all i had to hand) to make new studs. i carefully made them the same length as the original and then refitted the manifold to the car without checking. guess what? the flange on the new one is thicker! so out came my new studs and new ones made, all was well....

next i had to set up the VNT side of the turbo, not anything like as complicated as it sounds. you use a vacuum pump to measure how much vacuum it takes to start moving the arm, then you adjust the length of the rod coming out of the actuator until it meets the factory spec.

then i fitted the turbo, took about a hour, and sorted the injector washers. used a injector seat cutting kit to clean up the sealing surface, new washer and torqued to spec, so its running properly now. which is nice.

finished about 10 mins ago, so not a bad time for the job, would have been a lot quicker if i hadn't been peeing round with studs....

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Re: It seemed like a good idea at the time...

Post by qwakers » Wed Sep 11, 2019 8:00 pm

got started on the ramp slides/runners/storage today.

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a lot of fabrication work goes into stuff like this, so im not ever half way on one side, predominately because it was raining all day...
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Re: It seemed like a good idea at the time...

Post by qwakers » Thu Sep 12, 2019 7:07 pm

ramp frames completed, just gotta shorten the ramps and fit the end panels and lights...



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Re: It seemed like a good idea at the time...

Post by warpc0il » Thu Sep 12, 2019 11:16 pm

I can't get this out of my head


Nearly as bad as me driving my Alfa into the back of a 45Ton artic, using two lengths of Armco as rams, and trying to stop before hitting both our bikes that had already been loaded and parked broadside half-way-down, with all our furniture stacked up beyond.... :shock:
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Re: It seemed like a good idea at the time...

Post by qwakers » Fri Sep 13, 2019 7:12 pm

ramps shortened, hinges swapped to the top so they fold the other way, rear panel fitted and braced to the chassis.

nearly done!

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Re: It seemed like a good idea at the time...

Post by qwakers » Sat Sep 14, 2019 7:05 pm

i was planning on finishing the fab work and painting the unpainted parts today, until at about 1pm i got a call from my parents, who had gone to a farm machinery auction and bought a quad and trailer (drove there in the merc slk) and then wondered how they where going to get home. so most of the afternoon i spent driving up and towing it home for them...

did get the light pods done though..

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looks much better than just bolting the lights to the panel...
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Re: It seemed like a good idea at the time...

Post by zippyonline » Sun Sep 15, 2019 10:27 am

I'm impressed, not only does that look like reasonably hard work - it's being done outside on a less than brilliant surface!
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Re: It seemed like a good idea at the time...

Post by qwakers » Sun Sep 15, 2019 10:43 am

and without mains electricity either! (well, 100m of extension so i can run a grinder but any big tools not so much...)
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Re: It seemed like a good idea at the time...

Post by warpc0il » Sun Sep 15, 2019 11:08 am

The way battery technology is going, I wonder how long it will be before we have affordable cordless TIG welders.

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