16 years ago
design was too long. To fix it, I have to cut 3" out of it in each of 4 places
and weld it back together, the end to be approximately 12" shorter. The first
one I did was real straight, and I was happy until I did the second one. Shoot.
The piece is over 16 feet long, very awkward to handle. Would one of you
experienced guys please take a crack at telling me the real way to do this?
Here's what I did: (work piece is 1-1/4"x.120 wall square steel tube)
started with 2 sawhorses separated by about 12 feet
cut out the first section, deburred the ends
took a piece of 3x3x3/8" angle (heavy) and clamped it to splice, 1/16" gap
(NOTE: the inner radius of the angle iron is smaller than the outer radius of
the tube so it clamped solidly)
tacked it on the two available sides & removed the angle
-- at this point it was very slightly bent towards the tacks
ground a vee on the other two faces (the ones that had touched the angle)
welded one solidly
then, turned up the opposite side from the one just welded
ground away the tack & ground a vee & welded solidly
checked - very straight
then welded the 3rd side previously with ground vee
then ground away the tack and ground vee & welded the 4th side
The first time I did this, it came out very straight indeed. The second time the
segment was farther towards the middle, and it didn't come out straight.