The Worst Welds We've EVER Seen
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- čas přidán 24. 07. 2024
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Welcome back to Lift Arc Studios! Today, we're tackling the challenge of removing and fixing some of the worst welds we've ever seen on aluminum, specifically on a glass transportation truck. Using the HTP Pro Pulse 220 MIG welder, we'll start by carefully grinding and chipping away the defective welds to expose clean, bare metal. We even went as far as to cut new aluminum channel to attach to the truck body.
With the old welds removed, we can utilize the HTP Pro Pulse 220 to lay down new aluminum welds with the MIG gun. By the end of the process, the truck will have strong, aesthetically pleasing welds, ensuring it can safely transport glass without risk of failure. We even spoke to the young gentleman who did the original welds and we're happy to say he's improved since doing these particular welds. Stay tuned to see the transformation!
Chapters:
00:00 Intro
00:38 Learning MIG Aluminum
08:08 Truck Work Begins
21:09 Removing Old Welds
29:01 New Aluminum Base
33:56 New Welds Begin
35:36 Final Thoughts
40:36 Weld Redemption
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Produced & Hosted by: Tay Whiteside
Filmed by: Tay Whiteside and Walker Hooper
Featuring: Aaron Dykstra, Spike Geffert
Edited by: Walker Hooper
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Any technique or methodology shown in this video is purely for entertainment and informational purposes only. Lift Arc Studios and their associated craftsmen are not liable for any injury or damage to your shop or surrounding areas you man incur while trying to emulate these builds. Remember, be safe, have fun, work smart! - Jak na to + styl
well, always push, dont pull the weld, always vertical up never down, go in a straight line, no gun manipulation and high argon flow rates are your friend ...... just in a nutshell
Strop dragging, weaving and bobbing. Pushweld aluminium. With a slight angle with the gun/torch
That’s what I’m here to say
+1 Push wire pull stick.
The original welds are what happen when you forget to turn on the gas. As a couple other people mentioned you PUSH aluminum mig, you get way less spatter and it wets in much better. No patterns needed, just pull the trigger and move in a straight line, this stuff freezes faster than 6010.
that’s the ole “did it in the rain with a stick and a tractor battery”
Push when welding Alum!
Best WTF challenge of 2024 appreciate the ending 🤘
Here in my local area of south central Kentucky, for a decade or two we were known for our houseboat industry. The hulls and railings were all MIG welded aluminum. Pretty much Miller machines were all used in production with Cobramatic push-pull torches with leads up to around 30 feet. I guess it was to meet expectations of what someone would thing welded aluminum looks like but every visible bead had to be the old stacked dime bead. Lake Lanier in Georgia and Lake Cumberland here in KY are probably the largest collection of boats from all the factories. The economy changed and most of the factories closed. Some merged and now live on as a small conglomerate type thing I guess. I would have loved to have bought some of the equipment from them. It was a good job getting out of high school in the mid to late 90's. Especially on road crew/service. Delivering the boats and spending your summer on the lake was great in the summer. Service jobs were even better and less restrictive. Spent most of the time driving from small job to the next doing service. Good times. I guess the point of this mess is the HTP has some nice features and they are nice machines but are not necessary to MIG aluminum.
Using a little WD-40 prolongs the life of blades as well as improves and speeds up cuts on aluminum. Just a tip from 23+ years experience as well as every old timer I ever learned from when working with Aluminum. Also always preheat your starts and into your welds on Aluminum Spool gun/MIG. Even in some cases with thick 6061 TIG will give better results. TIG however preheating can be done with your TIG torch if done correctly.
"Maybe we shouldn't show the company's name" 13 seconds later it's not blurred 😂 13:12
That wasn't actually the logo from their company 😅 but went ahead and fixed that blur anyways, just in case... thanks for the heads up! - Walker
Man...one of THOSE jobs you never expect to survive to come to you for repair! I like Aaron's style - I like to wear ear muffs pretty much all the time in my shop. Helps with my concentration and peace of mind!
Very cool that you gave an update on the original welders skill level. 👍
sensible person would just decline any practice welds that would go down the road
Another training session. This guys take the time to get it right. Thanks guys.
Brother, you have not seen the worst in welding. Until you've seen mine.
I am glad the old "welds" chipped off with a chisel cleanly.
Those aluminum blades are called a “triple chip” style. The first tip is cut at a 45 degree angle, one third in on each side, and is approximately .005” shorter than the next tip. The second tip is cut square. The first tip is meant to make the bulk of the cut, while the second tip cleans it out and cuts the corners.
For how bad it was y'all did a grate job, not to mention that it was the first time you used a aluminum MiG welder, so for what its worth great job.
I'm not a welder, but even I could see that was a bad weld. So much fun to watch. I was a carpenter and we have a wood that is so hard we use metal-tools to cut it. And I have cut some alu too with woodworking tools
Great video
Im disappointed in youtube. It never gives me lift arc notifications. The only plus is i have hours of content to catch up on.
I heard that welder in other videos and with the pulse settings it sounds like a trumpet and welds like magic.
Tay, I always wondered what happen to you and the crew from Salvage Dogs. Loved that show and was truly sad when it ended. I may just have to check this out. Good luck in your business. Tell everyone at BD hello. Ron
Teflon liner in the torch lead and the rollers are half round to stop squishing the wire good luck
Good tip to use any old candles and wax your grinders discs to help cutting and grinding
Cheers from Aus
I dont see any issues here. Compared to some of my welds, these look pretty good. If you just crank the power really high, it will burn through the dirt and grime so you don't really need to clean.
Seen the kid's pictures at the end, they are all steel welds and are looking great, but aluminum is a whole different animal. I got to admit I'm impressed those goobers he put down stuck. At least he can say he glued two pieces of aluminum together; I can't say the same
was gonna make the same observation myself... let's see his aluminum welds now....
I saw a person run a bead and was able to peal it off with plyers . 😂
Totally bought a shirt!! Happy to help.
Great video, my problem is I was about to buy a spool gun for aluminium. I do like the idea of a short distance from wire spool to tip, to avoid bird nesting. Also being able to use long cable and pipe runs. The mig set up looks great, but I do feel you would be very limited on cable length. Have you tried other spool guns, other than the one you didn't like.
You guys arent used to working on Other tradesmens work trucks, OBVIOUSLY - if theyre in the field, and something breaks, they jam a screw in it, drill a hole and pop rivet, chewing gum, spit & Bailing wire, zip ties, etc -
Your repair looks good, I would say if you think about the forces on those triangle brackets you welded directly to the new strips, every time they hit the gas at a light in that truck with several hundreds of pounds of GLASS on the racks, those flat plates are going to flex, every time they hit the brakes, they will flex more, the welds are just a flat plate in a T configuration, sideways and will eventually fail again within a year or less- Gussets wouldve helped, also dont use regular plain black socket headed allens face up to catch and fill with rain water, regular hex-head bolts wouldve been fine- it's a work truck, not a race car
Temporary repairs are fine, but this was botched all over. It was more than a point failure and repair. Besides, poor welds are still poor welds no matter when they were made. I agree about the socket screws, unless they were stainless. But there’s no reason to have a little pot to hold water.
Lol you've never seen my welds
Open up that MR-1 already!
Yea! Forget welding.... Let's check out the langmuir systems MR-1!
Cool video tho.
You can use a teflon liner. I use a MT800 spool gun on a 250 amp ESAB mig master. I see miller has some welders that work good but they are expensive, Not to say ESAB was cheap. What I have is older technology.
Always push when mig aluminum for proper gas shielding.
Nothing worse than fixing bodge jobs but you got it sorted, good job! Next time use the pulse or double pulse function with hot start and crator fill, 4t trigger mode. You'll be amazed at the results. Cheers.
I have had some pretty bad welds walk through the door of our shop as well, the worst one was a weld that I peeled up with a set of chanel locks, absolutely zero pen.😢 good job fighting trough the pigeon shit...😂😂😂
Chris @ T-Town Welding and Fab.
That’s how professionals do it!
Do you charge by the hour for consultation time?
18:10 “I don’t know what that means”.
You are correct sir. 🥃
You spent a lot of time ranking on some guy that is just trying to get to his real job.
He knew he needed it done right, and when he found you, he ran with it.
But huge kudos to him for figuring out how to get to work the next day, in spite of his lack of knowledge in your particular field.
I lost a lot of respect for this channel today.
Yeah, generally not a good idea to punch-down on your customers - make a habit of that and word soon gets about.
Dude doesn't need telling how shit his welding is, that's why he's brought it to them. Shut the fuck up, be humble, do the job your customers paying you to do.
In before "As a professional welder with over 30 years experience...."
Peter Zila is a wizard a setting mig up for aluminum.
Nice Langmuir MR1 CNC gantry mill
Modern art is to Art what internet memes are to philosophy
I'm not even sure you could call that poop "welding"! I also now know that if I ever run into anything remotely close to this, I can just use a chisel and a hammer to get rid of it. no grinder necessary!
The shop steward that let that out the door should really look into a set of glasses. A new young welder is one thing. A steward not checking their work is quite another. I'm glad to see the young man is working hard to grow his skills.
Those old weld beads shown at the end looked like aluminum turds! Turds of a weld for sure. Aaron did a great job fixing the mess that was that rack. pre-heating to get a better start is a secret mostly because people are too lazy to bother with it. Out of sight out of mind!
are we just going to ignore the MR-1 in the box or what??!!!
Yup!
its cool that you allowed him tell him he to save face he is rooking welder but use 100% argon and not mixed gas
And then the owner we're gonna place a glass or Granit or what ever panels on the rack that can weigh up to 6-800kg ( 12-1600 pounds ) And that was driving beside you all in the traffic. Classic...
I’ve had some pretty horrible repair welding come in my shop to get fixed. One time an old cowboy brought in a piece off a crop sprayer to get fixed ( that he welded on I bet 4 times before) and it was by far the worst pigeon shit welding is ever seen. When I was done repairing it I asked him to bring his sprayer to fit the piece back on and I asked him to bring his welder as well…..he asked why he needed to bring his welding machine? …..I said “ cause I’m gonna run it the fuck over with my truck!!!!” He just laughed and has been a repeat customer for years haha. He doesn’t fix anything himself any more. 😅
amazing!!
I visit LARP and Medieval Events regularly as a LEather Worker. I often repair Shoes, Leather Belts and Pouches. Small Stuff, but the People I help are really grateful, and I never run out of Beer :-D
Dijkstra did alright welding aluminium but push it and that heating up is always better cos aluminium needs a lot of heat.
you mentioned penetration but arent aluminum welds surface welds?
I had a guy that brought a trailer in that was that bad. I had to charge for redoing of everything
Push your MIG welds, don't pull. You don't need to weave, but you can use a whip and pause on heavier alum. Use some pulse, enough gas to get a clean weld, and just play around with your machine to find what settings works the best for your situation.
I like the new, foul mouthed LAS. Makes me feel more at home. Please keep saying bad words!
We can all sleep better and feel completely safe about the fact that all of us are driving behind loads secured by welds and jury rigged quick fixes like this all the time.
Slightly Negative rake blade for the saws for Acrylic and or Aluminum is well worth the $$.
23:29 work actually begins
love it
11:20 They're rivets. _Just drill them out and life the cage up on some blocks._ Rivets aren't expensive.
I’ve never seen welds this bad. They just popped off when hit. I don’t know what to call them, calk maybe? I wonder if whoever made these even knew to weld with pure argon and possibly used 75/25?
Those welds won't last long. As soon as that truck hits a good bump it will flex and crack the welds. I would of used angle brackets, grade 8 bolts, washers and nylon locking nuts.
As a welder/fabricator of 95% aluminum work, ripping aluminum on a table saw is still my least favorite past time
Y'all just jealous of those beads and rivets! 👀🤣🤣🤣🤣
JB Weld would've been better than those original welds if you wanna call them welds.
they make by metal, not just aluminum use them all the time to cut aluminum, but wood carbide work just as fine just don't push it to fast or ill grab and you will have a bad day.
that's chit weld no doubt about it.
I don't think those were welds. I think someone tried using those aluminum brazing rods.
It had no welds, it had brazings.
Not even that. Razing sticks.
You Gents need an air chisel!!! Also those look like poorly done aluminum brazing rod turds, not welds.
So many fasteners the shit is starting to look like meccano.
Always push welding ali and increase gas flow.
Carbide tipped wood blabe only
Those old edges look like a cheap ass concrete screed. 🤷♂️
Drill the rivets down you’ll have that thing off in 10 minutes
poor aaron
If its got slag, let it drag. It doesnt have slag.
Yes i did know :)
That doesn't look welded to me, it looks "brazed" with aluminum rods you get off Amazon.
_Don't ask me how I know._
#Spike’sNewTherapistAaron 😱
For the love of Valhalla, wear a damn respirator when welding aluminum. Your older self will thank you when you dont get lung cancer from welding
Judging from the first few seconds that looks like somebody mixed JB-weld with siliconcarne :|
I see your Ave reference;)
@@LiftArcStudios :0 damn. I didn't even know he said that! lol
That was a genuine shocked sicstar statement. ^^
And those "welds" really look ... unique ... worked as a machinist and I never ever saw anything remotely that horrible nor have I any idea how in the everlasting f they managed those... or had the audacity to ship those.
Now I'm off trying to find where Ave dropped that line.
Keep it up!
I could try on purpose to do worse.
These videos are really hard for me to watch. Three guys who don’t know how to weld aluminum spending forever setting up a machine from a manual then standing around talking shit about someone else’s work who is likely the customer that did the shitty work lol. Then they stand around forever again trying to decide how to go about the repair. Guys get to work and get it done. This is typical daily shit in a fab shop you don’t need to have a meeting of the minds on how to repair it
yeah bad welds go look at the RV industry the frames on the trailers are questionable
sorry
You’re making me cringe.
STOP dragging the wire. You need a decent push angle upwards of 20° forehand. The push combined with the gas will create a cleaning effect.
Dragging or even having a neutral gun angle will put soot all over your finished weld
I would be shocked if either one of you guys reply to my question
Hmm been watching you for a while now generally like what you do But not impressed with the way you have bagged out the previous Fabricator. There is no need for that it doesn't add any value to be so disrespectful. After all it could have been the guys dead Father did that work couldn't it?. Very uncool in that regard guys. By all means inform and educate but don't do it at someone else's expense.
as you are cutting the person that welded this project could it been his first attempt ? i would like to see both of you guys first attempt welding this kind of material.
If you watch to the end, we ended up talking to the guy who welded this together! He said he thought it was funny and took it on the chin, and indeed he was early in his welding career. As we mentioned, everyone has to start somewhere
You shouldn't be doing your first welds in something structural that has to hold weight on a moving vehicle. When you're learning, stick to decorative or at least low speed applications like tractor attachments that aren't going to cause huge issues when it fails. Also, all the rivets and bolts show they knew it wouldn't hold.
I did watch to the end, but I was thinking you guys should have maybe didn't beat the guy up so bad ... Sorry if I upset you guys... Just my opinion
No worries at all! We had a few conversations on if we went too hard, but after talking to the guy we decided it was okay to post. I'm sure our first welds aren't anything pretty either
No problem and also thank you for your reply... I know my first welds were terrible as well. Take care
Looks like a good work environment. Spend all day working with your friends. Absolutely cool! WWG1WGA 🇺🇸 MACHINIST FOR TRUMP WWG1WGA 🇺🇸
8:17... That's not a Weld... It's badly done Glue or Epoxy.....😂