Actually cj is correct, if you used a horizontal mill with a carbide mill you could set the angle in a fixture and mill the proper angle into the tube, that is exactly how other people are doing it. The key is in being able to hold the tube at the proper angle so when you move the mill table into t...

You don't want a hole saw if you plan to use 4130 tubing. You want carbide mills, especially if you can get your hands on a horizontal mill. you will still need some type of filtering jig for angular alignment to position the tube end for milling. That can be made easily enough from some aluminum p...

One thing to consider would be making your own tube notcher. Many people use a hole saw to create the coped area to fit the tubes together. If you had a jig that would let you offset the hole saw, you could move it around so that you can create the proper fitting for most any angle the tubes fit to...

Just jumping back in from my original post.... I've done a lot of thinking of the last few days and have been watching the posts and gaining a lot of good information. I do think that some of my issues with porosity, when welding steel nuts to steel plate, comes from the zinc plating on the inside ...

GrundleJuice, (I like that name! :D) As you may know, when some of these hosting sites started to crack down on folks hosting their images, it turned into a huge problem, notably Photo Bucket. They started to ban people from third party hosting and BAM! much of the woodworking and metalworking comm...

There are some guys that do this on horizontal mills, notably old Nichols mills. You can pick them up pretty cheap and it would be a good option if you're mechanically inclined, which I would hope you are if you're building bicycle frames. :D Josh's reply of a tube notcher is spot on, I just don't ...

I think you have porosity in your camera lens... :roll: Anyway to get better pics? open them in a new tab I have to admit my ignorance here, amazing how clear the pics are in a new window when I "view image". :oops: On many of the pics I upload you can click on the pic, but those can't, n...

A bit late, but perhaps it will be useful for someone in the future. These hole cutters make clean, straight holes and will cut all but the hardest steel without much problem. I've used them for years, money well spent. Looks like they go up to 1.5" https://www.blairequipment.com/rotabroach-cut...

Welcome. What kind of materials are you going to use for the frame. There are several bicycle builders around here. And several old posts on the topic. Yes, I saw a couple threads with some bicycle talk. I plan to use some type of steel. Maybe 4130, maybe something more bicycle specific. Butted wou...

you stated that you are using a #8 clear cup, I see a 5 alumina in the picture. Also, I see the everlast machine,,,I have one and had a problem with the gas solenoid intermittently sticking... when you light up, can you hear the solenoid opening up? Also, you state that the problem starts after you...

The stickout by itself doesn't look too bad, but we can't see how far you actually have the tip from the puddle. Even so, I'd say you have contamination entering the shielding gas one way or another. That's why you have porosity and the orange dust of death. With your telephone-pole sized filler ro...

Double post!

I blame Tapatalk

A 1/8" tungsten is not too problematic IF you know to put a long sharp taper on it. We're not there to see what you're doing in that respect, so that's up in the air. A #7 cup is fine, so is 15-20 CFH of Argon flowrate. The problem is most likely you have too much tungsten stick-out AND you ar...

I am new to the Forum and have a question regarding preventing porosity. I'll do my best to be brief, but can supply additional details if needed. I have a ~ 2006 Miller Syncrowave 200 TIG machine and have been TIG Welding for about 13 years. I do a lot of Race Car Fab work for myself. I have been ...

Hello and thanks for reading. I had been TIG welding occasionally at my previous job with no formal instruction and was enrolled in a local CC TIG welding course for this spring that has since been cancelled for obvious reasons. Hoping to pick up some experience and really learn the basics and good ...