allright welders... school me in warpage. - Pirate4x4.Com : 4x4 and Off-Road Forum
 
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Old 10-26-2004, 12:48 PM   #1 (permalink)
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allright welders... school me in warpage.

ARRRGH.

so last night i decided to zip the buggy together (what i have of it fittted anyway) i went around and tacked all the bars at the quadrants, in hopes of keeping the chassis from warping significantly.

Well that didnt work. My whole roof section bowed a good 1/4-1/2" down.

lets hear tips and tricks and methods to keep this damn warpage down.

Heres a pic of the roof, i was welding the top of the big ol center node when it warped. now i have a big fat rain catcher up there.

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Old 10-26-2004, 01:02 PM   #2 (permalink)
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Did you weld all those joints on the center node at once? If so, that was your problem. Should have welded all the joints on the outside of the Halo, then taken your time welding up the center node. If done all at once, thats alot of heat in one localized area. Weld one of the joints then go to the joint directly opposite of the one you just did. Makes kinda of a pain in the ass, cause you can't sit/stand in one place and do more than one weld, but will help keep the warpage to a minimum. Did you weld any of the lower sections of the cage before starting on the top? IE, did you start at the bottom and go up, or at the top and go down? Would have been better to start at the bottom going up, as the welds on the bottom would have helped reinforce while welding the top. Specially that center node.
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Old 10-26-2004, 01:08 PM   #3 (permalink)
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I started at the drivers floor, then pass floor, worked side to side, front to back. then up to mid level, same thing, then top, finishing in the center.
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Old 10-26-2004, 02:13 PM   #4 (permalink)
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You didn't jump around enough. I take it that you saying you finished up welding thecenter, that you sat there and welded it all the center up. thats alot of heat. I usually don't even weld all the way around a joint before moving to a the next point. Plus having substantialy larger than normal tacks (small stiches) everywhere before starting the full welding up of the tube work helps.
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Old 10-26-2004, 08:10 PM   #5 (permalink)
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since welds shrink a small bit upon cooling, you may have ran into problems by tacking either the bottom joints of the outside halo too much at once or the top of the center "node" too much at once. this would definitely pull the center down. you should place a tack on the top, then the next on the bottom to even out the warpage.
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Old 10-26-2004, 09:56 PM   #6 (permalink)
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how tight was the fit up on the weld joints big gaps means big pulls, you will get alittle shinkage when the weld cools it shrinks a little but uasully will go back to its origanl form. anything i build or built whether its been a crane base or piping oil lines in a pre-lube i brace it off while i am building the rest and then welding it, jason.
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Old 10-27-2004, 08:01 AM   #7 (permalink)
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I always jump around to different points when welding, and preferably try to
weld on opposite sides of a section. even knowing that you can't eliminate
all warpage, you can also brace sections as well.

I've even "guesstimated" warpage on some stuff, and pre-loaded it the
opposite direction. welded up the assembly, then removed the pre-load
materials.......... sometimes it's perfect, sometimes not. it's better than
doing nothing at all though....

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Old 10-27-2004, 08:54 AM   #8 (permalink)
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Did you tack the bottoms of the tubes before you tacked the tops? You should have tacked the tops first, therefore pulling them up a hair, and then when you hit the bottom hopefully pulling them back into place. Vs. the bottom first, because them they have to overcome gravity to move back up.
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