Winter Contest Project #4 Stage light rain enclosure at Rawhide Western Town

[sw2x]

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I work for a company that does alot of the HVAC work for the Gila River Indian Community. Recently I welded a wheel for a co-workers dolly. My boss was so impressed by the quality of the welds that he's taking on small fabrication work for our HVAC clients. From welding cracks in food service equipment to building stands for package units. This project is rather unique tho.

The Gila River Indian Community runs a small theme park called Rawhide which is a 1800's style western town. They have a small show called the 6 Gun Theater. Where they shoot blanks at each other out of revolvers and fall off a 30ft roof after being shot. Really entertaining and funny show. Anyways they have indoor style stage lights, mounted on the top of the surrounding roof tops by unistrut, everytime it rains they destroy $1200 worth of bulbs. They asked us to come up with a cover that would protect them from the rain and be large enough to not overheat the bulbs. So my boss thought of building it out of uni-strut but I knew that it would not look professional nor would it be very sturdy. So I order up 120' of 1" x 1" x .060" steel tubing and welded together a frame to cover the lights and protect them from the rain. I'm going to attach sheet metal to the frame and use some hinges to make a access door for maintenance or repair.

I used 3/32" 2% Thoriated Tungsten, #7 cup with a stubby gas lens set at about 30cfh. I was having severe problems welding on the roof and the wind from south mountain was blowing my sheilding gas all over the place. I really need a MIG WELDER!!!!

Anyways heres some pictures. (The guy in the pictures is my co worker who I was teaching how to prep metal and how to measure angles...) Had to redo a few things after he fit it and I welded it, I also changed the front a bit because we royally screwed up on how we fit 2 tubes together. I have since fixed it but haven't been back out yet to install the sheet metal to get some pics...

[DVA]

That is a lot of work for Tig Welding. If you have a project like that it would be faster to stick weld or to use a mig welder with flux core wire.

[sw2x]

Yea I know... I dont have a mig welder and I tried stick welding for the first time last friday and it made a massive mess. Tig welding that took forever.

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[DVA]

A flux core welder does not cost too much and a lot of time could have been saved. Probably would have paid for itself on the first job.

[sw2x]

Yea, Ive got another thread on here regarding a mig welder purchase. Im buying one this week just dont know whether it will be a everlast or not. Depends on price and portibility.

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[ShaneJackson]

I'm in the same boat. My solar panel tracker frames are very big and have too much welding for TIG (but that is all I have right now...) I am the lucky 2nd place winner of last contest so I have some Evergreen bucks to use on a MIG... got to call Oleg this week or go to horror freight and waste some $$ on a temp solution until the 2013 MIGS are out.

[sw2x]

There is going to be a updated mig welder from everlast??

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[ShaneJackson]

That is my understanding. I called to order one back in November and was told if I didn't need one ASAP to wait for the new one.... I did but the TIG's were first to be updated and released so the MIG's are still on the back burner. Looks like April at best ... I really cant wait any more and I dont want to mess with HF junk (done it 1 time before and it went back to the store) so I have to call Oleg when I get a chance.

[sw2x]

I would really love to see a digital mig capable of operating on 120v and 240v 1ph. Using both flux core and regular wire with shielding gas. Ohh and I forgot lightweight... haha

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[DVA]

I would really love to see a digital mig capable of operating on 120v and 240v 1ph. Using both flux core and regular wire with shielding gas. Ohh and I forgot lightweight... haha

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You will love any MIG welder compared to trying to use TIG all the time. If you do not have a MIG welder or $$$, I would practice stick because it can be faster than TIG welding for the time being. I love my TIG welder but must admit that sometimes it is not very practical for many of my projects and just simply too slow of a process when not needed. I have been using it to practice my pipe welding so I can pass a radiograph welding test someday. I say someday because I need some more stick practice.

[sw2x]

I really have no desire to stick weld. Just too messy. I would have to invest more $ in leather to protect myself from slag. Rather buy a mig welder.

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[ShaneJackson]

I really have no desire to stick weld. Just too messy. I would have to invest more $ in leather to protect myself from slag. Rather buy a mig welder.

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I'm in the same boat. I have never stick welded and really don't think I would like it. I figure my stick weld would look worse than bubba's $9hr welds

[ShaneJackson]

Fore those who have no clue what I am referring to:

[aaxiss]

I was tig welding most everything under 3/16" and stick welding anything thicker. Got a mig welder about 6 weeks ago and love the versatility can go from sheet to 1/4 plate in seconds now and the welds are great looking, even with the torch in the hand of a gimp like me.

Pull the trigger (no pun intended ) and at least buy a decent flux core mig unit.

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[sw2x]

Yea, im just waiting on alex to call me back. So I can decide which mig I should be buying.

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[sw2x]

Watched the bubba video lmao. Thats funny. If I ever have to apply for a job again, I will have to pull a similiar stunt.

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[DVA]

You do not need leathers to stick weld. Just use 7018 and watch your body position. I use a green welding jacket and gloves with no issues when practicing 6G position pipe welding.

[Rambozo]

You do not need leathers to stick weld.

Shorts and a tee shirt are probably a little light for 4F & 6G.

[youngnstudly]

The HVAC shop I worked in was very similar to your job. Lots of typical stuff, some "off the wall" stuff, and once in a great while I would get to go out into the field and work on something extra fun. I can't say I've ever welded on a theme park job, but it sounds fun!

As for the MIG welder, I've been wanting one myself for quite a while! TIG welding everything is slow, and stick welding is out on my thinner/delicate projects. If you think the MIG and stick welding are night and day difference on mess they create, they really aren't much different. Flux core wire is really similar to stick welding, while shielding gas is a little more clean.

You will still walk away from working and have grit in your hair, eyes, teeth, and on your skin though. Sometimes you just have to get down and dirty. Other times, you'll choose to TIG simply for the cleanliness!

You do not need leathers to stick weld. Just use 7018 and watch your body position. I use a green welding jacket and gloves with no issues when practicing 6G position pipe welding.

Green welding jacket and gloves? Are you sponsored by Everlast? I want a "gig" like that! Where do I apply?

[aaxiss]

For me the leather adoption is a must as everything falls in my lap while welding. Tig is the best as far as no sparks and I try to use that process when I want a nice lookin weld and I'm not in a hurry. But mig and stick (the worst for potential injury and fire ) throw off a lot of sparks and hot junk. Already had one shoelace fire this year lol.

Imagine the potential damage, me sitting in my wheelchair with all those sparks falling right in my lap..... :banghead:

I'll stay with the leathers. Got a nice set of Goatskin sleeves that are really nice when it's cold out and some fire resistant Miller sleeves for the summer months. Got a half jacket also I like the best. Doesn't add too much heat and is good protection. I think it's BSR or something like that and was under$20

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