Welding Essentials: Questions and Answers

Chapter 15: Fabrication & Repair Tips

If a little knowledge is dangerous, where is the man who has so much as to be out of danger?

Thomas Huxley

Introduction

This chapter contains step-by-step instructions for performing some of the most common welding, brazing, and soldering tasks. There are details on how to make rectangular frames, put legs on a table, and make a three-dimensional solid frame. There are also instructions for repairing cracked truck frames and welding on vehicles. In addition, there is a section on pipe and tubing repairs and tools. Finally, a procedure for soldering copper tubing is given.

Rectangular Frames

What are two ways to make angle iron corners for a rectangular frame?

Mitering and notching. See Figure 15-1. Both methods work, but a beginner might find notching easier, since it is more dimensionally tolerant. After welding and grinding both will look equally good.


Figure 15-1: Mitered (left) and notched (right) frame corners.

Is there another approach to making rectangular frames from angle iron?

Yes, see Figure 15-2. This approach works well when a notching machine is available and lends itself to production work. Getting the correct bend allowance gap is critical, because it provides the extra material needed to go around the outside of the corner when the bend is made Figure 15-2 (a). Begin by setting the bend allowance gap to slightly less than the thickness of the angle iron and go from there.


Figure 15-2: Notching and bending to make a single-piece frame: (a) Corner detail before bending, (b)...

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