Welding Tips and Tricks

Started thinking/planning about it when my crappy 2x72 cobbled up grinder motor died in early Jan 2021, and I started actual welding in March 2021. I still have to weld the work surface to the work arm this coming weekend, and re-do the belt covers (I burned through the thin metal!), but it is actually running now: Baldor Industrial 3PH, 3HP motor with an VPF

Started by removing the inside weld seam in a couple of square tubing pieces:






Although I did make most everything from scratch, I did buy the "C" bracket assembly from Origin Blade Maker. Since it is my own design, I have no plans - I adjusted as I went along. Here I am clamping everything to get an idea of spacing, length, etc..




Cut and milled the top arm, and even made some delrin spacers for a slight press fit:







This is the mockup (clamped in early April) - nothing welded yet:



Once I figured the spacing to get all wheels aligned, I started welding - 100% with my new to me HTP 201 water-cooled Tig Machine:

Welded a spacer for the rear to hold the two pillow bearings:






Instead of on the side, I wanted a handle at the end, so I capped the movable arm:





Note the adjustable/trim piece for the top wheel I also got that assembly from Origin Blade Maker:

Late April, main body welded - another mockup with clamps:


How I tested various springs:



Fitting the drive wheel:







Custom delrin to get spacing perfect against the bearing:



For the base, I used a scrap piece of about 1/2" I found while doing cleanup with my son's Boy Scout camp in a local creek:



Took a lot of sanding to get the bulk of the rust:




And then vinegar (works great to remove mill scale!):

Welding the main frame to the base - all of this square tubing is 1/4" wall:







Occasionally I got a decent looking Tig weld:



Then started working on the stand (1/8" wall)

Getting closer:



To being able to do small adjustments on the spring for the top arm, I made up and welded this small piece:





I was initially going to make a movable arm for the VFD from scratch, but found a $20 brand new arm - hard to pass up:



Made and welded a simple bracket to hold the VFD:

One side:



other:




Then wire motor and VFD:

Still need to weld this piece:



But here is the running grinder/stand:









My first Tig project. About 4 months, done a little bit every weekend

nicely done

Thanks - it was fun and great practice.

Very cool build. Probably take a decade of my spare time but does look like fun.