Making a Pair of Side Rails Part 2

One thing I didn't understand was how you squared and centered the backrest plates. Very nice work on the buggy and the video.

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Originally posted by BeamerBob One thing I didn't understand was how you squared and centered the backrest plates. Very nice work on the buggy and the video.

Ok...I could have used a center square, but lol, I am a Fabricator....If I cannot see when a plate is vertical at this stage of my life, I am in the wrong game....so the answer to your question Bob is...I eyed them up.

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Originally posted by popeyethewelder Quote: Originally posted by BeamerBob One thing I didn't understand was how you squared and centered the backrest plates. Very nice work on the buggy and the video. Ok...I could have used a center square, but lol, I am a Fabricator....If I cannot see when a plate is vertical at this stage of my life, I am in the wrong game....so the answer to your question Bob is...I eyed them up.

If it looks right................ It is.

popeye's got built in laser level in his head :singing: He's just not letting on but he's a terminator from the future

Again, such wonderful work Popeye. You are a true master! It is awesome that you are making all of this free to the public. Your creations are inspiring and your talent is amazing. Thank you for all you do for the kiting community.

Popeye, here in the states Discovery channel airs a show called Biker Build-Off. where two fabricators build choppers for braggin rights. on the episode i just saw, this Japanese guy named 'Chica' was heating and bending frame rails by hand. ever seen this done...?

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Originally posted by cheezycheese Popeye, here in the states Discovery channel airs a show called Biker Build-Off. where two fabricators build choppers for braggin rights. on the episode i just saw, this Japanese guy named 'Chica' was heating and bending frame rails by hand. ever seen this done...?

The only time I have seen tube bent with heat is when it is filled with sand...copper tube, I have never seen stainless done this way and would be surprised if it could be..

Always a great vicarious thrill.

So even with the plates tacked on at several points around the tubes, it can distort when finishing the full weld if not in the jig, huh?

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Originally posted by acampbell Always a great vicarious thrill. So even with the plates tacked on at several points around the tubes, it can distort when finishing the full weld if not in the jig, huh?

Yes...tig welding pulls like a steam train, on the swan neck plates for instance, if the tube either side is not cut perfectly onto the plate and there is a gap on one side, by the time you have welded it up it may have moved or pulled the plate a 1/4 of a degree, now that does not sound much, but transfer the 1/4 degree up the length of your swan neck and the top will be 10mm out or more, and will not only look wrong , but your forks will also the be angled and not 90 degrees to the ground.

So...the message here is, if you do not have a jig, cut the tubes well, add plenty of small tacks around the tube, tack on opposite sides from the previous tack....when you start welding just weld a quarter of the tube, then weld the opposite side etc etc, I have made 30 odd buggies without a jig, and as long as you take your time and follow the comments above you should not have much trouble.

If once welded up you notice the swan neck is tilted over, you have no choice apart from cutting the weld, there may not be any need to cut the whole plates off, but depending on which way it is tilting, with a slitting disc in a mini grinder, you can slit the top half of one side and the bottom half of the other, then with the swan neck fitted, start tacking the slits in the tube, you will see the swan neck become upright and sitting proudly at 90 degrees.

Thanks Professor! fascinating stuff

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Originally posted by acampbell Thanks Professor! fascinating stuff

lol @ professor....you going to NABX Angus

Yeah looks like it. Trying to work out the budget for the wife, too.

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Originally posted by acampbell Yeah looks like it. Trying to work out the budget for the wife, too.

See you on the Playa....I bet my budget to take my wife too works out a bit more though lol

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Quote: Originally posted by popeyethewelder The only time I have seen tube bent with heat is when it is filled with sand...copper tube, I have never seen stainless done this way and would be surprised if it could be..

Popeye ,we do it all the time. You need a steel fab table to weld lots of little flat bar stops on. Then you tack the pipe down next to the stops and start heating the pipe until orange hot. at this poin the stainless is pliable but easily damaged or if you get it a little too hot it will go liquidus on you. A pipe bender is the way to go.

And if ya need to straighten up a slight bend , heat the opposite side red hot then apply wet rags on it which will cause it to shrink on that side thereby pulling it in that direction. You would be amazed at the things that can be fixed by forced shrinkage. There is a science to it for sure.

We have used heat and a CO2 fire extinguisher to get shafts sraight enough to move a mechine in the gravel pit in the past. Ugly thing to do but it got us to a better place to work on it!!