- Joined
- Oct 13, 2010
- Messages
- 6,055
- Country Flag
Aux Fuel Tank, Excavator Bucket, AirBoat & Tool Box.
OK guys update time.................................
I spent the whole of last weekend practicing my welding.
![DSCN0521_zpsxzswcik5.jpg DSCN0521_zpsxzswcik5.jpg](https://www.landcruiserclub.net/community/attachments/dscn0521_zpsxzswcik5-jpg.97821/)
Sunday evening I decided to do a bit more on the fuel tank project.
Welded the fuel sender unit boss next.
![DSCN0522_zpsbtacearu.jpg DSCN0522_zpsbtacearu.jpg](https://www.landcruiserclub.net/community/attachments/dscn0522_zpsbtacearu-jpg.97822/)
![DSCN0523_zpsmymkjbsr.jpg DSCN0523_zpsmymkjbsr.jpg](https://www.landcruiserclub.net/community/attachments/dscn0523_zpsmymkjbsr-jpg.97823/)
![DSCN0524_zpsvy4no6cd.jpg DSCN0524_zpsvy4no6cd.jpg](https://www.landcruiserclub.net/community/attachments/dscn0524_zpsvy4no6cd-jpg.97824/)
![DSCN0525_zpspechsjus.jpg DSCN0525_zpspechsjus.jpg](https://www.landcruiserclub.net/community/attachments/dscn0525_zpspechsjus-jpg.97825/)
![DSCN0526_zpsp6jhf1xv.jpg DSCN0526_zpsp6jhf1xv.jpg](https://www.landcruiserclub.net/community/attachments/dscn0526_zpsp6jhf1xv-jpg.97826/)
![DSCN0527_zpsifrhwvtk.jpg DSCN0527_zpsifrhwvtk.jpg](https://www.landcruiserclub.net/community/attachments/dscn0527_zpsifrhwvtk-jpg.97827/)
Welded the 2 main sections of tank together.
![DSCN0528_zpssavfinf5.jpg DSCN0528_zpssavfinf5.jpg](https://www.landcruiserclub.net/community/attachments/dscn0528_zpssavfinf5-jpg.97828/)
![DSCN0529_zpsbgcbrls7.jpg DSCN0529_zpsbgcbrls7.jpg](https://www.landcruiserclub.net/community/attachments/dscn0529_zpsbgcbrls7-jpg.97829/)
![DSCN0534_zpsssd3i7zj.jpg DSCN0534_zpsssd3i7zj.jpg](https://www.landcruiserclub.net/community/attachments/dscn0534_zpsssd3i7zj-jpg.97830/)
![DSCN0535_zpsxugt1yeq.jpg DSCN0535_zpsxugt1yeq.jpg](https://www.landcruiserclub.net/community/attachments/dscn0535_zpsxugt1yeq-jpg.97831/)
That was as much as I got done on the fuel tank last weekend.
At work this week I had an unusual project.
My boss had bought the perfect sized bucket he needed for his 5 ton excavator. Only issue was it wouldn't fit, so my job was to make it fit.
I got him to bring a bucket that does fit in, so I could copy the mounting system.
![DSCN0536_zpshjcz9wnj.jpg DSCN0536_zpshjcz9wnj.jpg](https://www.landcruiserclub.net/community/attachments/dscn0536_zpshjcz9wnj-jpg.97832/)
![DSCN0537_zpsh46svnrf.jpg DSCN0537_zpsh46svnrf.jpg](https://www.landcruiserclub.net/community/attachments/dscn0537_zpsh46svnrf-jpg.97833/)
My first job was to cut off the mounts on the new bucket.
![DSCN0538_zpsjwnggq0m.jpg DSCN0538_zpsjwnggq0m.jpg](https://www.landcruiserclub.net/community/attachments/dscn0538_zpsjwnggq0m-jpg.97834/)
![DSCN0539_zpst5oidc3i.jpg DSCN0539_zpst5oidc3i.jpg](https://www.landcruiserclub.net/community/attachments/dscn0539_zpst5oidc3i-jpg.97835/)
The oxy torch worked well for this.
![DSCN0541_zps6rf3xanr.jpg DSCN0541_zps6rf3xanr.jpg](https://www.landcruiserclub.net/community/attachments/dscn0541_zps6rf3xanr-jpg.97836/)
![DSCN0542_zpsx6lfgli7.jpg DSCN0542_zpsx6lfgli7.jpg](https://www.landcruiserclub.net/community/attachments/dscn0542_zpsx6lfgli7-jpg.97837/)
New mounts.
![DSCN0543_zpsktxrppq9.jpg DSCN0543_zpsktxrppq9.jpg](https://www.landcruiserclub.net/community/attachments/dscn0543_zpsktxrppq9-jpg.97838/)
![DSCN0544_zpsq82gscj3.jpg DSCN0544_zpsq82gscj3.jpg](https://www.landcruiserclub.net/community/attachments/dscn0544_zpsq82gscj3-jpg.97839/)
![DSCN0545_zpsp8pvcl1y.jpg DSCN0545_zpsp8pvcl1y.jpg](https://www.landcruiserclub.net/community/attachments/dscn0545_zpsp8pvcl1y-jpg.97840/)
I gave the template to a local steel company that we use. They specialize in cutting sheet steel and have got sheets of steel up to 400mm thick x 12ft square!![Surprised :icon-surprised: :icon-surprised:](/custom/images/smilies/pack2/icon/surprised.gif)
Its where I got my bench top from.
Anyway......................
They cut me 2 pieces out of 20mm plate.
![DSCN0550_zpsb4b1uikd.jpg DSCN0550_zpsb4b1uikd.jpg](https://www.landcruiserclub.net/community/attachments/dscn0550_zpsb4b1uikd-jpg.97841/)
![DSCN0551_zpsy7p1amg6.jpg DSCN0551_zpsy7p1amg6.jpg](https://www.landcruiserclub.net/community/attachments/dscn0551_zpsy7p1amg6-jpg.97842/)
![DSCN0552_zpsxoj6nsqk.jpg DSCN0552_zpsxoj6nsqk.jpg](https://www.landcruiserclub.net/community/attachments/dscn0552_zpsxoj6nsqk-jpg.97843/)
![DSCN0553_zpsjmnsflnr.jpg DSCN0553_zpsjmnsflnr.jpg](https://www.landcruiserclub.net/community/attachments/dscn0553_zpsjmnsflnr-jpg.97844/)
Cleaned up the bucket ready for welding.
![DSCN0554_zpsehyvtwgh.jpg DSCN0554_zpsehyvtwgh.jpg](https://www.landcruiserclub.net/community/attachments/dscn0554_zpsehyvtwgh-jpg.97845/)
![DSCN0555_zpsliabu4vx.jpg DSCN0555_zpsliabu4vx.jpg](https://www.landcruiserclub.net/community/attachments/dscn0555_zpsliabu4vx-jpg.97846/)
I cut some 90mm squares of 12mm plate and hole-sawed a 40mm hole in the center of each.
![DSCN0557_zpssxx4b4qe.jpg DSCN0557_zpssxx4b4qe.jpg](https://www.landcruiserclub.net/community/attachments/dscn0557_zpssxx4b4qe-jpg.97847/)
Beveled the edges to ensure good weld root penetration.
![DSCN0559_zpshce8eq4t.jpg DSCN0559_zpshce8eq4t.jpg](https://www.landcruiserclub.net/community/attachments/dscn0559_zpshce8eq4t-jpg.97848/)
Welded the squares on.
![DSCN0560_zpsrc6xlcyw.jpg DSCN0560_zpsrc6xlcyw.jpg](https://www.landcruiserclub.net/community/attachments/dscn0560_zpsrc6xlcyw-jpg.97849/)
![DSCN0561_zpsmd06smd4.jpg DSCN0561_zpsmd06smd4.jpg](https://www.landcruiserclub.net/community/attachments/dscn0561_zpsmd06smd4-jpg.97850/)
The 40mm round bar I had picked up turned out to be 43mm.![Doh! :doh: :doh:](/custom/images/smilies/pack2/eusa/doh.gif)
I cut the 2 pins and spun the ends down in the lathe to 40mm to fit the 90mm squares and 20mm side plates.
I ground the edges of the 20mm thick plates to again ensure good root penetration on the welds.
Tacked the pins in position.
I then hung the bucket on the vice and fully welded it.
He has a quick hitch on his machine, so no need to remove the pins to fit the bucket. I welded the pins in position with 3 small welds so that if the pins do ever wear and need replacing it shouldn't be too hard to cut them out.
All done.
A quick coat of paint.
I brought my TIG in to do some more on the air-boat project.
I welded the huge piece of tube onto the front.
I then fully welded all the external seems/butt joints.
The back of the boat cracked when we folded the 5mm thick sheet of alluminium.
I chose to cut out the crack before fully TIG welding it.
For this I picked up a special blade for the angle grinder which is basically a small circular saw blade.
Normal cutting and grinding discs quickly clog up when cutting or grinding alluminium, but this little blade was awesome!
I was expecting a lot of kick back but there was virtually non and it cut so quickly and smoothly. It also worked amazingly well for grinding down the alluminium in places where I had got far too much penetration.![Clapping :clap: :clap:](/custom/images/smilies/pack2/eusa/clap.gif)
Cut out ready for welding.
TIG'd.
I also welded the tube on on the back of the boat, meaning all of the welding was now done and the hull should be water tight.
I decided to lift the boat up into the air so I could weld the front tube to the hull in a more comfortable position.
I could then put the boat back the right way up on its pallet.
The next job is to start adding the ribs inside the boat which should stiffen it up a lot.
I spent half an hour on the lathe turning a piece of the 43mm bar down.
Not quite up to Chris's standard of lathe wizardry but I was pleased with the end result.
Can you guess what it is yet?
Cut it to length on the brobo saw.
My boss gave me a load of rusty old clamps that were covered in concrete which he got in a job lot of tools from an auction.
I cleaned all the rust and concrete off easily with the wire wheel on the big 3 phase bench grinder.
But one of the Record clamps was missing a piece and that was what I turned up on the lathe.
Good as new!
I've wanted to bring my big tool box home from work for a while now. I've got a nice little workshop setup in my garage but I was always finding that I needed tools that were at work or that I was using shitty old screwdrivers and pliers when I had really good ones at work.
I also found that I didn't use half of the tools in my box at work and didn't need anywhere near as much tool storage at work, yet I did at home.
So I've brought my big tool box home and I will take a smaller one into work with a selection of the tools I use the most.
I also picked up a metal cabinet to lock all my power tools in.![Very Happy :icon-biggrin: :icon-biggrin:](/custom/images/smilies/pack2/icon/biggrin.gif)
I machined up loads of pieces of pipe on the oxy pipe beveler at TAFE the other night so I can keep practicing all weekend.
And finally back to the fuel tank.
I attempted to do some more welding on it this afternoon.
It really is horrible stuff to weld.![Thumbdown :thumbdown: :thumbdown:](/custom/images/smilies/pack2/icon_thumbdown.gif)
Even after trying to grind the layer of alluminium off and wiping it all clean with thinners it still doesn't weld nice.![Doh! :doh: :doh:](/custom/images/smilies/pack2/eusa/doh.gif)
It has also warped and twisted in places from the heat of welding it. In hindsight normal steel would have been better and then I could have just got it electroplated.![Thinking :think: :think:](/custom/images/smilies/pack2/eusa/think.gif)
But then I got thinking........................
I'm using 2mm thick alluminiumised steel that Brown Davies use for all of their tanks that go underneath vehicles and cop a lot of abuse off road.
Where as with my tank being inside and reasonably well protected I should have just used alluminium.
It would be a hell of a lot lighter, easy to machine, cut and drill and would weld beautifully.![Thinking :think: :think:](/custom/images/smilies/pack2/eusa/think.gif)
So I'm thinking of scraping what I've done so far and starting again in 3mm alluminium.![Shifty :shifty: :shifty:](/custom/images/smilies/pack2/eusa/shifty.gif)
If a job is worth doing its worth doing right, even if that sometimes means admitting you've made a mistake and costing yourself more time and money.![Thumbup :thumbup: :thumbup:](/custom/images/smilies/pack2/icon_thumbup.gif)
OK guys update time.................................
I spent the whole of last weekend practicing my welding.
Sunday evening I decided to do a bit more on the fuel tank project.
Welded the fuel sender unit boss next.
Welded the 2 main sections of tank together.
That was as much as I got done on the fuel tank last weekend.
At work this week I had an unusual project.
My boss had bought the perfect sized bucket he needed for his 5 ton excavator. Only issue was it wouldn't fit, so my job was to make it fit.
I got him to bring a bucket that does fit in, so I could copy the mounting system.
My first job was to cut off the mounts on the new bucket.
The oxy torch worked well for this.
New mounts.
I gave the template to a local steel company that we use. They specialize in cutting sheet steel and have got sheets of steel up to 400mm thick x 12ft square!
![Surprised :icon-surprised: :icon-surprised:](/custom/images/smilies/pack2/icon/surprised.gif)
Its where I got my bench top from.
Anyway......................
They cut me 2 pieces out of 20mm plate.
Cleaned up the bucket ready for welding.
I cut some 90mm squares of 12mm plate and hole-sawed a 40mm hole in the center of each.
Beveled the edges to ensure good weld root penetration.
Welded the squares on.
The 40mm round bar I had picked up turned out to be 43mm.
![Doh! :doh: :doh:](/custom/images/smilies/pack2/eusa/doh.gif)
I cut the 2 pins and spun the ends down in the lathe to 40mm to fit the 90mm squares and 20mm side plates.
I ground the edges of the 20mm thick plates to again ensure good root penetration on the welds.
Tacked the pins in position.
I then hung the bucket on the vice and fully welded it.
He has a quick hitch on his machine, so no need to remove the pins to fit the bucket. I welded the pins in position with 3 small welds so that if the pins do ever wear and need replacing it shouldn't be too hard to cut them out.
All done.
A quick coat of paint.
I brought my TIG in to do some more on the air-boat project.
I welded the huge piece of tube onto the front.
I then fully welded all the external seems/butt joints.
The back of the boat cracked when we folded the 5mm thick sheet of alluminium.
I chose to cut out the crack before fully TIG welding it.
For this I picked up a special blade for the angle grinder which is basically a small circular saw blade.
Normal cutting and grinding discs quickly clog up when cutting or grinding alluminium, but this little blade was awesome!
I was expecting a lot of kick back but there was virtually non and it cut so quickly and smoothly. It also worked amazingly well for grinding down the alluminium in places where I had got far too much penetration.
![Clapping :clap: :clap:](/custom/images/smilies/pack2/eusa/clap.gif)
Cut out ready for welding.
TIG'd.
I also welded the tube on on the back of the boat, meaning all of the welding was now done and the hull should be water tight.
I decided to lift the boat up into the air so I could weld the front tube to the hull in a more comfortable position.
I could then put the boat back the right way up on its pallet.
The next job is to start adding the ribs inside the boat which should stiffen it up a lot.
I spent half an hour on the lathe turning a piece of the 43mm bar down.
Not quite up to Chris's standard of lathe wizardry but I was pleased with the end result.
Can you guess what it is yet?
Cut it to length on the brobo saw.
My boss gave me a load of rusty old clamps that were covered in concrete which he got in a job lot of tools from an auction.
I cleaned all the rust and concrete off easily with the wire wheel on the big 3 phase bench grinder.
But one of the Record clamps was missing a piece and that was what I turned up on the lathe.
Good as new!
I've wanted to bring my big tool box home from work for a while now. I've got a nice little workshop setup in my garage but I was always finding that I needed tools that were at work or that I was using shitty old screwdrivers and pliers when I had really good ones at work.
I also found that I didn't use half of the tools in my box at work and didn't need anywhere near as much tool storage at work, yet I did at home.
So I've brought my big tool box home and I will take a smaller one into work with a selection of the tools I use the most.
I also picked up a metal cabinet to lock all my power tools in.
![Very Happy :icon-biggrin: :icon-biggrin:](/custom/images/smilies/pack2/icon/biggrin.gif)
I machined up loads of pieces of pipe on the oxy pipe beveler at TAFE the other night so I can keep practicing all weekend.
And finally back to the fuel tank.
I attempted to do some more welding on it this afternoon.
It really is horrible stuff to weld.
![Thumbdown :thumbdown: :thumbdown:](/custom/images/smilies/pack2/icon_thumbdown.gif)
Even after trying to grind the layer of alluminium off and wiping it all clean with thinners it still doesn't weld nice.
![Doh! :doh: :doh:](/custom/images/smilies/pack2/eusa/doh.gif)
It has also warped and twisted in places from the heat of welding it. In hindsight normal steel would have been better and then I could have just got it electroplated.
![Thinking :think: :think:](/custom/images/smilies/pack2/eusa/think.gif)
But then I got thinking........................
I'm using 2mm thick alluminiumised steel that Brown Davies use for all of their tanks that go underneath vehicles and cop a lot of abuse off road.
Where as with my tank being inside and reasonably well protected I should have just used alluminium.
It would be a hell of a lot lighter, easy to machine, cut and drill and would weld beautifully.
![Thinking :think: :think:](/custom/images/smilies/pack2/eusa/think.gif)
So I'm thinking of scraping what I've done so far and starting again in 3mm alluminium.
![Shifty :shifty: :shifty:](/custom/images/smilies/pack2/eusa/shifty.gif)
If a job is worth doing its worth doing right, even if that sometimes means admitting you've made a mistake and costing yourself more time and money.
![Thumbup :thumbup: :thumbup:](/custom/images/smilies/pack2/icon_thumbup.gif)