Welds

[t_j]

I disagree, a proper mig weld should look like a stack of dimes, as well. At least from everything I was ever taught or seen.

Mig welds should be relatively smooth in comparison to the stack of dimes look from TIG. Lots laps in a mig weld indicates cold roll over and an incorrect speed and puddle control, some minor ridges are acceptable but they are very low profile in comparison to a TIG weld.

This is how I was taught at least.

 

[AZEngineer]

Mig welds should be relatively smooth in comparison to the stack of dimes look from TIG. Lots laps in a mig weld indicates cold roll over and an incorrect speed and puddle control, some minor ridges are acceptable but they are very low profile in comparison to a TIG weld.

This is how I was taught at least.

Exactly correct.

 

[t_j]

Well that is why I took pics and posted because to me it did seem somewhat amateur but I am not educated on welding techniques nor could hold a conversation with him in any regard. Yes I would like to make it right and now looking back, I paid way too much to have this done. A couple problems that I am concerned about.

1. The top of the lightbar hangs over the cab. It was somewhat close and did get hit it as there is 3 small dents up there from when it first failed. When this guy cut it off, we lost height. My thought with the thicker plate was we make up the loss of height. If we cut again and drill out so it can be welded from both sides then I am going to lose a considerable amount of height and probably be too close to the top of cab. This is my biggest concern, how to fix situation?

2. Just the ability to find someone GOOD that will do this so I can get it all done within time to get ready for Snoball.

3. It does not fit flat on the bed rails, it did not fit flat even in the beginning. Now it fits less flat because it is overlapping the tonneau cover rails. Good size gap really. I am thinking of taping off the corners and fill the void with some type of hardened type epoxy to make a custom platform so it has a flat surface. Ideas?

1) It does not need to be cut out, you can grind out those welds and run new ones over the top with little risk. You should probably heat treat the area after this.

2) If you where closer to Chi I would say head over and we can take care of it, but thats probably a little far for you. I would try to find a more reputable fabrication shop in the area and ask them to re-weld it.

3) Grind out the underside of the plate with an angle grinder in the area that it interferes with the rails.

 

[skyscraper]

In all honesty, for the intents and purposes of these particular welds, there is no problem outside of aesthetics. I would have it line-x'ed and call it good. You can stress over the welds all day but having them re-welded won't make any difference.

The base plate cracked in the first place, so maybe a thicker plate is needed. Those welds are fine, Jesus Christ we aren't talking about tig welding knuckles here, it's a light tower.

 

[Deleted member 12951]

The bed moves around a bit when off-roading if you look at my first pic where I have a nice kiss on the cab. I am going to try real quick to see if I can get someone to clean-up the mess and only if they can strengthen it. If not, I am just going to proceed with Line-X (they said they would do it Monday) and if it breaks again, then I guess I will spend the coin and do it with the sleeve idea to address the height issue. With on-going repairs, this is going to be the most expensive lightbar ever!

 

[Deleted member 12951]

Okay, I was talking to a friend and showed him the welds. He is an amateur welder but said he could do better than this bozo. He used a TIG and its not exactly pretty but to me is does look better plus he said he got it hot enough to penetrate and now there is a heat trace on the underside.

How do they look now, should hold better?

 

[t_j]

Looking way better.

 

[J DAMAGE]

Agree, way better than before.

 

[skyscraper]

The weld critic in me notices the porosity and undercut. But considering the application that will be plenty strong. When you coat it with line-x it will be smooth.

 

[Deleted member 12951]

The weld critic in me notices the porosity and undercut. But considering the application that will be plenty strong. When you coat it with line-x it will be smooth.

But its gotta be a better stronger hold now than what is was? Was more concerned of that than beauty.