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Posted 5/11/2017 4:58:22 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
Here is some information from my studies in hemi-joint threaded tubing insert welding.
MILLER WELDING FORUM: Hemi-joint threaded insert welding.
Note: Suspension and steering related hemi-joints are considered to be
critical welded parts in that weld/part failures could result in
severe injury and death. If you don’t have absolute confidence in your
parts/materials, welding, and weld testing, knowledge and abilities,
take them to a professional welder.
Here is the related posting.
“Now some will say they got nice hot welds on the bungs they did with
MIG. I do not know what their experience is but having a MIG weld go
in "nice and hot" is certainly no guarantee if it is sound or not.
Only practicing and destruction testing on your welds will show if
welding and parameters were correct. So, I buy some extra bungs and
weld them as practice. Once welded, I cut long and sideways through
the center and examine for fusion. This is the only way I can know for
certain. Anytime I change any variable such as tubing material, even
the thickness, hemi-joint threaded insert material/dimensions, welding
wire/rod, welder settings, etc. I destruction test the new welded
combination. It is the only way I can be certain that my welding and
parameters were correct.”
On many welding websites and forums I have observed a lot of
reluctance to discuss the exact specifics, such as, actual welding
techniques and methods, as well as, any recommendations for specific
MIG wires and TIG filler rods. Which I can understand given the
inherent major responsibility and liability risks associated with
welding suspension and steering hemi-joint threaded tubing inserts.
Post #156777
Posted 5/17/2017 7:20:49 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
Not really set up to do video but I plan to show in great detail how I
welded and tested by destruction my hemi-joint threaded tubing inserts
(bungs). This will be reflective of my unique and particular
hemi-joint threaded tubing insert (bung) welding experience and only
relevant to the variables related to my particular set of materials,
welding, and weld testing.  If the welding of my hemi-joint threaded
tubing inserts is successful, it is in no way a guarantee, that
someone else with a different set of materials, machines, welding
abilities, methods, and technique variables would achieve the same
results.
I currently have four extra hemi-joint threaded tubing inserts on
order to be used for welding and weld testing by destruction. I have
added  this from the Miller Welding forum

MILLER WELDING FORUM: Hemi-joint threaded insert welding.
Note: Suspension and steering related hemi-joints are considered to be
critical welded parts in that weld/part failures could result in
severe injury and death. If you don’t have absolute confidence in your
parts/materials, welding, and weld testing, knowledge and abilities,
take them to a professional welder.
Here is the related posting.
“Now some will say they got nice hot welds on the bungs they did with
MIG. I do not know what their experience is but having a MIG weld go
in "nice and hot" is certainly no guarantee if it is sound or not.
Only practicing and destruction testing on your welds will show if
welding and parameters were correct. So, I buy some extra bungs and
weld them as practice. Once welded, I cut long and sideways through
the center and examine for fusion. This is the only way I can know for
certain. Anytime I change any variable such as tubing material, even
the thickness, hemi-joint threaded insert material/dimensions, welding
wire/rod, welder settings, etc. I destruction test the new welded
combination. It is the only way I can be certain that my welding and
parameters were correct.”
Post #156800
Posted 5/17/2017 7:23:52 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I posted a copy of this post here because it might be of some benefit
to anyone planning, starting, or currently building a B V S DOJ Bat Mobile.

Here from weldguru.com is the best and most comprehensive article I
have ever seen on the web for assessing and testing the quality of
welds. I put the table of contents below. Go to weldguru.com to read
the whole 2593 words on the subject. It is very informative and worth
reading for anyone interested in, and/or worried about the quality of
their welds.  vertigo

Guide to Weld Quality Testing
“To ensure the satisfactory performance of a welded structure, the
quality of the welds must be determined by adequate testing procedures.
Therefore, they are proof tested under conditions that are the same or
more severe than those encountered by the welded structures in the
field.”

This page contains visual inspection tips. The following pages contain
inspection methods for GMAW and physical weld testing.

Table of Contents

Visual Inspection Methods

Lack of Fusion

Undercutting

Incomplete Penetration

Slag Inclusions

Porosity

Gas Weld Testing

Physical Weld Tests

Acid Etch Test

Guided Bend Test

Free Bend Test

Back Bend Test

Nick Break Test

Tensile Strength Test

Hydrostatic Test

Magnetic Particle Test

X-Ray Testing

Gamma Ray Testing

Flourescent Penetrant Test

Hardness Tests

Magnaflux Tests

Electromagnetic Tests

Acoustic Emission Testing

Ferrite Testing
Post #156801
Posted 5/18/2017 7:55:39 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I posted a copy of this post here because it might be of some benefit
to anyone planning, starting, or currently building a Bat Vehicle.

Here is one the most comprehensive websites I have found for MIG welding.

Weldguru.com

“Hi, my name is Garrett… (owner of weldguru.com)

For the past 5 years I’ve helped well over 10,000 beginners and
hobbyists get started learning to mig weld through my free training.
If you’d like to get started, Download my FREE beginner’s guide to MIG
welding.”
Post #156813
Posted 5/19/2017 8:15:42 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I posted a copy of this post here because it might be of some benefit
to anyone planning, starting, or currently building a Bat Vehicle.
With the recent postings focus on welding I have decide to post on a
question frequently asked of me by those interested in or new to
welding.

“What is the best start out welding book for someone wanting to learn
about or improve on their minimal welding abilities?”

The best current book that meets the needs of those wanting to learn
about or improve their minimal welding abilities is: The Art of
Welding

It really has no current competition in succinct to the point
descriptive text or quality of photo images and illustrations.

Many Junior High schools, High schools, colleges, and welding schools
now use this as their 101 welding introduction text.

The Art of Welding
by  William Galvery
former Professor of Welding Technology
Orange Coast College of California
With input from Ryan Friedlinghaus
Founder and CEO of West Coast Customs
Copyright 2014
Industrial Press
32 Haviland Street
South Norwalk, Connecticut  06854
Toll free: 1-888-528-7852
www.industrialpress.com
Standard Edition:  ISBN 978-0-8311-3475-4
Praxair Edition: ISBN 978-0-8311-3488-4   (this is the edition I have)
Cost approximately: 20.oo
Post #156824
Posted 5/24/2017 7:47:32 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I placed a copy of this post here because this information on tire
temperature effects on dimensional variables may be of some use to
someone planning and/or building a Bat Vehicle.
Interco list them as 44 x 18.5-16.50
One spec sheet refers to a Tire Diameter Range:
44.0-44.99 inches
At 70 degrees cold the tire is 44.0 inches tall
Once the tire starts rolling, and/or the temperature increases, the
tire will expand.
Throughout the operational range the tire is not supposed to expand
more than an inch in diameter.
There is no information on the range of width expansion throughout the
operational range.
I guess they don’t consider the width expansion variation as important
since the tires were not envisioned to be used in a dually
configuration. Probably the same reason there are no 16.5” dually
steel wheels for these tires
Post #156853
Posted 5/25/2017 7:57:47 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I placed a copy of this post here because this information on
tire-loading calculations may be of some use to someone planning
and/or building a Bat Vehicle.

Calculated the weight factor parameters for my Tumbler.
Each SAM-43 Super Swamper max loading 2855 lbs
X 4 = 11,420 lbs
Each Mickey Thompson front tire max loading 1500 lbs
X 2 = 3,000 lbs
Combined max loading weights = 14,420 lbs
In reality I can only use a factor of 1500 lbs per tire X 6 = 9,000
lbs for any weight loading above axle or in front of the rear tires.
6 equal points of ground contact X 1500 lbs = max loading of 9,000 lbs.
Needed front tires rated at 2855 each to get the full max loading of 11,420 lbs
So, I will try to keep my total Tumber weight around 8,000 lbs or less
but will have 9,000 lbs as a maximum possible total weight if I should
need it.
If I needed a little more tire weight carrying capacity above 9,000
lbs I would have to add some weight back behind the rear axle. The
fulcrum effect would tap into the lost 5,420 lbs of max tire loading
from the rear tires.   vertigo
Post #156867
Posted 5/26/2017 6:49:56 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I placed a copy of this post here because this information on
welding up a horizontal triangulated upper axle mount may be of some use to someone planning
and/or building a Bat Vehicle.
Welded up horizontal triangulated upper axle mount for my GM 14 bolt axle truss.
I will most likely use the triangulated 4-link suspension in my B v S DOJ Batmobile when I begin construction. vertigo


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Post #156877
Posted 7/5/2017 7:36:34 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I placed a copy of this post here for anyone planning to build a Bat
Vehicle that may find it useful.

A good example of the benefits of procedural order and modular finishing in Bat Vehicle building.
Pre-installation grinding, sanding, polishing, finishing, and painting assemblies like an axle before installation will save you many hours of work and avoid a lot of aggravation.

“A bit of advice, if you can try and paint and finish bits like
your chassis, etc. as you’re going along. It becomes a real pain
coming back removing bits and pieces and proper access to parts
becomes awkward.” paulwayne

I like the way great minds think the same.

Like you suggested, I plan to paint and finish build part groups as I
go along. That’s why I didn’t mount the axle to the chassis mounts
before stopping to build the rear panels with recessed propane gas
tanks.
As you suggested, I plan to paint the rear axle with POR-15 before I
physically suspend it on the four-link suspension.
The axle with welded on truss will take some time to paint to get
inside the truss. I expect I will need to rotate the axle assembly
around 360 degrees, a little at a time, to be able to reach everything
with the POR-15 coating. If I had mounted the axle before painting, it
would have made coating the axle a major ordeal.
vertigo
Post #158044
Posted 7/6/2017 7:10:50 PM
Supreme Being

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Last Login: Yesterday @ 9:32:18 PM
Posts: 1,567, Visits: 2,528
I posted a copy of this post here because it might be of some benefit
to anyone planning, starting, or currently building a Bat Vehicle.
What I learned from welding my hemi-joint threaded tubing inserts.
Used standard tactical spaced welding techniques to equalize heated metal expansion and contraction forces.
In spite of rigorous application when the hemi-joint was screwed in it went in easily until it reached a point inside equal to where the threaded insert was welded to the tubing.
When I checked the concentricity (equal roundness) inside it was in round.
So why did the threaded hemi-joint bind.
Called the father of a friend if mine, a retired NASA metallurgist that specialized in extreme welding while working in the space program.
Here is his answer:
"Hemi-joints that thread into threaded tubing inserts will bind if the threads are cut to normal standard fit because when the insert is welded around the outside, the thermal forces from the welding create an inward pressure on the inside threads. It is also the reason that a thread cutting tap is used as standard procedure to true up the threads. The ones that don't bind have much less tightness in their thread fit to address the thermal welding forces."
So, I will be buying right and left hand taps. vertigo


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