UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING, AND SPECIAL TECHNIQUES
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UNIVERSAL BAT VEHICLE: WELDING, TOOL MAKING,... Expand / Collapse
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Posted 11/8/2017 5:30:27 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
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Received a personal email that asked:

“What kind of MIG welder are you using to weld your wheels?”

My whole steel wheel welding project is being completed with a 200.00
oxy/acetylene cutting torch and a used 100.00 Lincoln stick welder set
on 120 with 6011 rods, as a tribute to the potential builder who is
waiting to start a Bat Vehicle build until they have acquired the
right tools. Inspiration and tools are 1% and the rest is study,
perseverance, determination, and perspiration.

I like to describe it as: THE COURAGE TO BUILD IN THE FACE OF
ADVERSITY.  vertigo
Post #159833
Posted 11/8/2017 6:38:46 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for anyone that might be able to
benefit from it in planning to, and/or, actually building a Bat
Vehicle.

Here is one area that I increase the production output of my building hours.
WELDING
With my Lincoln stick arc welder I can run 5 rods in 7-8 minutes
before it needs to cool down for 10-15 minutes. Also, know as the duty
cycle. So I run 5 rods welding on my Tumbler and while the welder
cools down I use that 15-minutes to work on another area of my Tumbler
build.
I could use the same method with my MIG. It too, can only run so much
wire before it needs a cool down. (Duty cycle) Unless, you have a MIG
gun that circulates water to keep it cool. Then you have a 100% duty
cycle.

To find your welder's duty cycle check your welder's manual.
The duty cycle has two parts: The total cycle time and the work time /
cooling time, usually expressed as a percentage.
Example 1: Duty Cycle:  10-minutes / 20%
This means per ten minute period you can weld for 2-minutes and need
to cool for 8-minutes.
Example 2: Duty Cycle: 10-minutes / 40%
This means per ten minute period you can weld for 4-minutes and need
to cool for 6-minutes.
vertigo
Post #159838
Posted 11/10/2017 5:31:33 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for the potential benefit of anyone
planning to, and/or, actually building a Bat Vehicle.

The Thinking Steps to Solve Complex Systems Bat Vehicle Building
Problems:  Example: the Tumbler front suspension.

Albert Einstein, “Problems cannot be solved using the same level of
thinking that created them.”

Part of the problem of thinking about a complex vehicle building
problem is the way we approach it. A quick overview of common vehicle
building problem solving techniques indicates that most of these
methods focus on the problem (linear relationships) without
consideration of its relationship to the external problem environment
where the problem exists. (Linear Blindness.)

Systems thinking, developed by Jay Forrester of MIT attempts to remedy
the limitations of linear problem solving.

The idea is described in his book, The Fifth Discipline, as follows:
“Systems thinking is a discipline for seeing wholes. It is a framework
for seeing interrelationships rather than things, for seeing patterns
of change rather than static ‘snapshots. A common example of the
systems thinking method is the life around us where multiple systems
interact with each other and are affected by each other.”

Complex system problems that involve different factors, which require
understanding the big picture in order to be efficiently solved such
as constructing the Batman Tumbler front suspension or re-configuring
the Batman v Superman DOJ / Justice League Batmobile from 12 feet wide
to a street legal 8-1/2 foot vehicle.

Situations that are affecting, are being affected by, or affect the
surrounding systems, such as the skill level of the Bat Vehicle
builder, financial resources, and the base of operations. (Your
available building space and its tolerance of building noise.)

 Concepts of Systems Thinking

In order to understand systems thinking, a number of concepts should
be highlighted in order to define the relation between the problem and
the other elements in the system and how to observe this relation in
order to reach an effective solution. These principles include the
following.

 All systems are composed of interconnected parts, and changing one
part affects the entire system, including other parts.

 The structure of a system determines its behavior, which means that
the system depends on the connection between parts rather that the
part themselves.

System behavior is an emergent phenomenon. System behavior is hard to
predict due its continuously changing, non-linear relations and its
time delay. It can’t be predicted by simply inspecting its elements or
structure.

Feedback loops control a system’s major dynamic behavior. The feedback
loop is a number of connections causing an output from one part to
eventually influence input to that same part. The number of feedback
loops are larger than the system parts, which contributes to
increasing system complicity.

Introspective bias and errors in thinking will produce
counterintuitive behaviors.
Example: When I made the decision to straighten my Tumbler’s front
arms from an engineering perspective without consideration of the
artistic ramifications that it would produce.

Write it all down with sketches as needed.
“If you are not writing it down, you are only daydreaming.” Einstein

Systems Thinking in Three Steps

Set 1: State the Problem, understand and describe it and the whole
system relationship rather than individual parts.
Example: I need to build the Tumbler’s front suspension.

Step 2: Draw possible solution behaviors out over a continuity of time
continuum. A desk top calendar or line graph (vertical or horizontal)
This is the in order, step by step planning, and includes, adding,
and/or, improving and missing or deficient skills.
Example: Tumbler planning/building steps and in my case study welding
jigs and fixtures.

Step 3: Create a Summary Focusing Statement
At this point, you should have a clear vision about the Bat Vehicle
system problem solving process. Write a statement that defines the
target problem and overall problem(s) solving plans and strategies.
vertigo
Post #159852
Posted 11/13/2017 6:21:46 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for the potential benefit of anyone
planning to, and/or, actually building a Bat Vehicle.

One very important thing I learned when working out the rear dually wheel setup on my Tumbler is just how important it really is to mount one of the rear SAM-43 Super Swamper tires on a 16.5 x 12 inch rim and weight loading the setup with 1500 lbs of weight before taking relevant measurements. My rear dually setup plan is to have 2-2.5 inches between the dually mounted tires. Had I not taken the time to do this set up testing prior to planning my rear dually setup I would have made some major measurement errors as the attached photo-images illustrate. vertigo


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Post #159866
Posted 11/13/2017 6:45:24 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for the potential benefit of anyone
planning to, and/or, actually building a Bat Vehicle.
Finished everything including final painting on one of my rear outside dually wheels and 90% of welding on the other outside dually wheel.
Could not resist placing my two non-mounted SAM-43 tires against the sides of the two finished axle mounted tires to see what the four dually mounted wheel will look like. vertigo


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Post #159869
Posted 11/15/2017 5:32:04 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for the possible benefit to anyone
planning and/or building a Bat Vehicle

Relevant Tire Observations:

Tire construction, diameter, width, inflation pressure, temperature
(heated SAM-43 Super Swamper tire to 100-degrees with an electric
heater), and loading are all inter-related to the final tire
measurements.

The bigger the tire the more the measurement error differences between
the cold non-mounted and wheel mounted heated and inflated tire.
Note: Once tires begin to roll the friction between the road and
flexing of the tire begin to generate heat above the environmental
heat.

Not much of a problem with Bat Vehicles that use a fairly conventional
tire but a major relevant source of error measurement for the dually
spacing of the Tumbler’s rear tires and even more so for the Batman V
Superman DOJ/Justice League Batmobile fender well/assembly clearances.
vertigo

“One very important thing I learned when working out the rear dually
wheel setup on my Tumbler is just how important it really is to mount
one of the rear SAM-43 Super Swamper tires on a 16.5 x 12 inch rim and
weight loading the setup with 1500 lbs of weight before taking
relevant measurements. My rear dually setup plan is to have 2-2.5
inches between the dually mounted tires. Had I not taken the time to
do this set up testing prior to planning my rear dually setup I would
have made some major measurement errors as the attached photo-images
illustrate.”
vertigo
Post #159881
Posted 11/16/2017 6:20:21 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
Mounted outer dually tires.

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Post #159886
Posted 11/17/2017 6:05:14 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
Mounted my two outer rear dually tires on my Tumbler today.
Took some measurements from the total rear end setup.
Quite impressed with myself.

I was looking for 2 to 2-1/2 inches of spacing between the rear dually tires.
Measurements of the spacing today revealed my actual spacing to be 1-3/4 inches.
Very tolerable and should work just fine. vertigo



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Post #159892
Posted 2 days ago @ 6:00:57 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for the possible benefit to anyone
planning and/or building a Bat Vehicle.

Using welding rods/electrodes that have absorbed too much moisture is the number one cause of bad welds for the non-professional and home welder.

How to Prevent Hydrogen induced Weld Cracking and Porosity Problems.  Part One

Lincoln Welding Corporation

“Electrodes for Shielded Metal Arc Welding (SMAW) or stick electrodes
must be properly stored in order to deposit quality welds. When stick
electrodes absorb moisture from the atmosphere, they must be dried in
order to restore their ability to deposit quality welds. Electrodes
with too much moisture may lead to cracking or porosity. Operational
characteristics may be affected as well. If you've experienced
unexplained weld cracking problems, or if the stick electrode arc
performance has deteriorated, it may be due to your storage methods or
re-drying procedures.

Follow these simple storage, exposure and re-drying techniques to
ensure the highest quality welds, as well as the best operational
characteristics from your stick electrodes.

Storing Low Hydrogen Stick Electrodes

Low hydrogen stick electrodes must be dry to perform properly.
Unopened Lincoln hermetically sealed containers provide excellent
protection in good storage conditions. Opened cans should be stored in
a cabinet at 250 to 300°F (120 to 150°C)

Low hydrogen stick electrode coatings that have picked up moisture may
result in hydrogen induced cracking, particularly in steels with a
yield strength of 80,000 psi (550 MPa) and higher.

Moisture resistant electrodes with an "R" suffix in their AWS
classification have a high resistance to moisture pickup coating and,
if properly stored, will be less susceptible to this problem,
regardless of the yield strength of the steel being welded. Specific
code requirements may indicate exposure limits different from these
guidelines.

All low hydrogen stick electrodes should be stored properly, even
those with an "R" suffix. Standard EXX18 electrodes should be supplied
to welders twice per shift. Moisture resistant types may be exposed
for up to 9 hours.

When containers are punctured or opened, low hydrogen electrodes may
pick up moisture. Depending upon the amount of moisture, it will
damage weld quality in the following ways:

1. A greater amount of moisture in low hydrogen electrodes may cause
porosity. Detection of this condition requires x-ray inspection or
destructive testing. If the base metal or weld metal exceeds 80,000
psi (550 MPa) yield strength, this moisture may contribute to
under-bead or weld cracking.

2. A relatively high amount of moisture in low hydrogen electrodes
causes visible external porosity in addition to internal porosity. It
also may cause excessive slag fluidity, a rough weld surface,
difficult slag removal, and cracking.

3. Severe moisture pickup can cause weld cracks in addition to
under-bead cracking, severe porosity, poor appearance and slag
problems.

Re-drying, when done correctly, restores the electrodes' ability to
deposit quality welds. Proper re-drying temperature depends upon the
electrode type and its condition.

One hour at the listed final temperature is satisfactory. DO NOT dry
electrodes at higher temperatures. Several hours at lower temperatures
is not equivalent to using the specified requirements.

Electrodes of the E8018 and higher strength classifications should be
given no more than three one-hour re-dries in the 700 to 800°F (370 to
430°C) range. This minimizes the possibility of oxidation of alloys in
the coating resulting in lower than normal tensile or impact
properties.

Any low hydrogen electrode should be discarded if excessive re-drying
causes the coating to become fragile and flake or break off while
welding, or if there is a noticeable difference in handling or arc
characteristics, such as insufficient arc force.

Electrodes to be re-dried should be removed from the can and spread
out in the oven because each electrode must reach the drying
temperature.

(1) Pre-dry for 1 to 2 hours. This will minimize the tendency for
coating cracks or oxidation of the alloys in the coating.

Storing and Re-drying Non-Low Hydrogen Electrodes

Electrodes in unopened Lincoln cans or cartons retain the proper
moisture content indefinitely when stored in good condition.

If exposed to humid air for long periods of time, stick electrodes
from opened containers may pick up enough moisture to affect operating
characteristics or weld quality. If moisture appears to be a problem,
store electrodes from the opened containers in heated cabinets at 100
to 120°F (40 to 50°C). DO NOT use higher temperatures, particularly
for electrodes from the "Fast Freeze" group.

Some electrodes from wet containers or long exposure to high humidity
can be re-dried."
Post #159899
Posted 2 days ago @ 6:07:19 PM
Supreme Being

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Last Login: Yesterday @ 8:02:00 PM
Posts: 1,687, Visits: 2,621
I placed a copy of this post here for the possible benefit to anyone
planning and/or building a Bat Vehicle.

Using welding rods/electrodes that have absorbed too much moisture is the number one cause of bad welds for the non-professional and home welder.

How to Prevent Hydrogen induced Weld Cracking and Porosity Problems.  Part Two

Welding Rod/Electrode storage issues.

In a low humidity 70-degree environment most welding rods have an
eight hour exposure time after the package is opened before moisture
begins to have some intruding effect on the rods.
High humidity will drop that to 4-hours.
Many structural welders don't use rods after 4-hours of air exposure.

If moisture appears to be a problem, you can store the remaining
electrodes from the opened containers in a heated cabinet at 100 to
120°F (40 to 50°C).

Welding rods/electrodes come in 5LB, 10LB, and 50LB containers.

Per pound rods sold in 50LB containers cost the least but require a
heated box to protect them from moisture.

I solve my moisture exposure risk by buying my welding rods/electrodes
in 5-LB sealed packages.

18-rod per pound X 5 = 90 rods

I usually weld at a stick use rate of 12-18 rods per hour depending on
the welding complexity of the project.

6011 rods cost me around 3.60 per pound (18.00 for 5 LBS)

I usually use most of a 5 LB package in 8-hours.

If any remain I seal them in a plastic tube bag with a vacuum food
sealer and write the time exposed to the air since opening the
original package. I also break down a 5-LB package, and immediately
seal them in plastic tube bags with a vacuum food sealer, 18-rods in 4
bags, 9 in 1 bag, and 3 in 3 bags. These I use for small welding
tasks. The stray rods with moisture laden flux coatings I hit against
my steel welding bench to knock the flux off, put them in a plastic
storage tube, and use them as weld filler material.

NOTE: I don’t use welding rods on my Tumbler with more than 8-hours of
total air exposure time since opening. I use the rods with more than
8-hours exposure for other general purpose welding tasks.
Post #159904
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