I used to do residential construction.... I have done the 60 cycle boogie more often than I really care to think about. (usually was just 110 though, still, quite a shock......) Makes me paranoid working on them now.

 

I used to hang iron for a construction company. Never welded for them, but we were up there while they were welding. And on wet mornings, you had to be careful how you touch or sit on the beams. It will send a spark through a wet glove, or even wet pants.

I havent been shocked by the welder yet, just burned by slag or sparks. I am an avionics installer by trade, so I work with electricity everyday, although its usually 28 volts or less. Im using a 220 plug at home for the welders.

 

Wear high top shoes/boots, and have your pants on the OUTSIDE of them. Don't ask me how I learned that.

 

Years ago i had to (stick) weld something on a metal platform(outside), While i was at it it started to rain. Well even with boots/gloves you will get zapped. One thing you may want to try is change the way you move the wire(mig). Meaning some people weld zig zag, "Z's" half circles or full circles etc. Depends on your preference but what i do most of the time are circles especially on thin metal(not sheet metal). I found it doesn't heat up the metal to much in one spot and you can keep a constant smooth puddle going. The cube look good!

 

Automotive electrics don't bother me. I've even shorted the secondary ignition with my hands to stop an engine quick when the oil line on a cooler blew. I've had watch bands short out hot wires and give an instant second degree burn. DC doesn't bother me. AC is what I don't like as the voltages and amps are so much higher.

 

I've brazed and also used a torch as a smoke wrench many times over the years. No matter how fast you get that shoe off when that slag drops down it, it isn't fast enough. I see these car shows where they build something and all the guys are wearing pants that stop just below the knees. I've been wearing my big boy pants since before I was 10.

 

Got a lot done this weekend. About 10 hours total, but I got the bed mounts fabbed and installed. I also verified the cab is leaning, so that explains the body lines not lining up. So, I removed the bed and welded the mounts and the rear cross member. Ill finish boxing the frame, add a tow hitch and some other supports. I still have to finish the 4-link welding too. Im still working on my welding. I think Im getting better, but I still need work.


Rough bed mounts. I cleaned and cut them before installation.

Bed coming off again.

Its getting easier. I got it this far by myself.

Mounts and rear crossmember are new additions

Another shot. Still a lot of work to do.

The welds are solid, because I ground a few out. They are penetrating good, but they look like catapillers for some reason.

 

Vertical welds are more difficult, Looks like you where travailing to fast. Practice on some scrap metal weld both top to bottom vs bottom to top and see what works best for you. Also tilt the gun around 45*(down) this will help keep the puddle from wanting to drop down.

 

I have watched a bunch of videos, and that is what I thought too. But if I go much slower, the weld sags. I guess I can turn up the welder, and try again. I still need a ton of practice. I have some overhead welds to do also. Those make me nervous. I also need to watch the nozzle angle as you mentioned. I used a triangle pattern going bottom to top on those welds.

 

I had a good 10-12 hours in the garage this weekend. Most of it was cleaning and welding. I went back and ground out some of the bed mount welds, and tried it again. But first I practiced on a spare angle piece I had, and tried a few things. Everything just looked like the caterpillar welds I was doing. I was talking to the welder at work (and remembered the posts above), and he suggested I go top to bottom, and slow down. I felt that was counter-intuitive. Gravity would make the weld sag, but out of frustration, I tried it. And it worked. I turned the machine up a little hotter, ran the wire feed a little faster, slowed down a bit and went top to bottom. I might have been pointing the nozzle the wrong direction as well. They look much better.

So, I finished up the welding on the rearend, and the bed mounts, then I finished the shock mounts and the cross member, and the boxing plates behind the rearend. A lot of welding, but it turned out good, I think. Now I can clean it up, and paint the frame. I still have to get the tow hitch receiver and brace it up but thats almost all the frame work.


They were penetrating, but not very good

Better. A little fat, but they are not going to fail.

This is in a good position, with a gap in between the parts. This is what I think they should look like.

Rearend out for final welding

4-link brackets finally all welded up. Just need some paint.

All done, and back in place. This is fully compressed and touching the frame. It will never get this high.