Latest Work Completed Mantua, New Jersey
Original Site:
September 2004
E-mail: usav8or@yahoo.com
Aircraft Welding 101: Part Too
or as I say, “Time in the saddle.”... continued
Lit up the torch on Monday, January 29th. Burning holes in 4130 is a lot easier to do than I thought it would be.
And YES, that's burning holes... not welding.
Ya gotta start somewhere... can't be thinking that I'll be an expert in just a few hours.
I'm past pushing around a puddle of molten metal. But, I haven't gotten past laying down a nice run of weld bead. Instead of
a nice raised series of rings I have something that looks like an oyster shell; yes, there is a series of ringlets that move along a line, but they're flat and kinda
washed out over a large wide area. It looks like I've got the flame too hot for the weld "joint." A little less heat and I think I'll be able to get the penetration in the
base metal that I need and also get a sufficient amount of weld on top, aka the throat, that is also needed for a structurally sound weld joint.
Not having taken a class, and with nothing but reading, a DVD and talking with a few builders, I wasn't exactly sure if my actual experience while practicing was taking me down the correct path.
My head was spinning... sorta like learning a new game, being inundated with ALL THOSE RULES at one time. But like learning to play a new game, I went with the flow. I wasn't looking to "win" the first time out, I just wanted to learn the "game," a few practice rounds.
First time laying a weld bead. (just above thumb)
After just a few hours of practice. Better weld lines.
My first few "hands" playing the "game" I was in limbo... I was on the right track but I knew that I wasn't doing it exactly right. I knew that if I continued "playing the game" it would reveal itself. I already knew how to do it, it was just
a matter of asking myself the right questions. Something was missing from the equation... I tried different ways of holding the rod to the flame, forming the puddle, different approaches to adding the rod to the puddle (DON'T allow dropplets to form and splash into the puddle) blah blah blah....
On the third night, about 15 mintues into the "session" I decided to try placing the rod into the puddle. When I touched that RG45 rod to that golden puddle it seemed to be absorbed by it. I started to massage it into it; feeding it almost. Lights and bells went off... DAMN ! that's
what it's all about. Worked the rest of the night at keeping the puddle going while at the same time "feeding" the right amount of rod to keep it happy.
I'm starting to get nice bead lines. My earlier lines of "bird droppings" are being replaced with raised series of rings, dark little caterpillars. The heavens had opened, golden rays of light beamed upon me, and a choir of angels began to sing in chorus. All had been revealed. Well, not all... when I snap out
of my "dream state" by a loud "POP" I saw that I had blown a hole into the piece that I was working on.
Well, at least I see that I'm on the right track with this welding stuff. Time to hang up the goggles and
call it a night. More time to practice tomorrow.
February 5, 2007: It's been a few days since practicing puddle pushing. The temps have been in the teens with wind chills
in the negative numbers. The garage isn't heated and old man winter is holding me back from blowing holes into anymore 4130. The weather is suppose
to break in about a week. Until then I'll continue building a few more ribs. I'm getting to the point of re-making a few of the older ribs that I've
completed because I'm not as happy with them as compared to my latest creations.
February 19, 2007: Well, the grip of winter is still upon us. The weather man is saying that by the end of this week we should be
seeing temps in the upper 40's to lower 50's. What are the odds that the weather man is going to be correct in his forcast for
the next day... let alone 3 days from now ? (thats a rhetorical question, by the way.)
If it comes to pass, with daytime weather like that, the night time temperatures should be in the upper 30's. It's a little bit
nicer to be out in the garage learning to weld with numbers like that. Go figure... I get all worked up to start welding, get all that
equipment and peripherals, and the temps go to hell. (don't mind me... I'm just venting right now.)
I was egar to bring a few specimens of my welding to the EAA Chapter meeting on Wed but that isn't going to happen.
March 4, 2007: The weather broke yesterday, Saturday, and temps got to about 60. NOW they're back into
the 30's with 25 - 30 mph winds. CAN'T wait any longer to get back to practicing welding. Lit the torch up and began to burn up some metal. A little rusty
even with my limited capabilities as a welder and I can tell that the month has taken it's toll on my "abilities" to weld.
Began to weld straight pieces of metal together. Obviously, it's fairly easy to weld together two flat pieces of metal, of the
same gauge. Now try that with two pieces of metal of various gauges. It's a LOT harder playing the puddle on two different metals than you'd think. Reading all the
books on the shelf about this stuff isn't going to equate to actually "saddling up the horse and riding it." If it seems like I'm repeating my self
here, it's because I am.
Ya wanna build a tube and fabric airplane? And you're thinking of building the wood wings first.... Do yourself a favor
and pick up a welding rig and get started at practicing your welding today. By the time you need to use that skill you'll
be an old hand at it. At least I had enough sense to get started with practicing half-way into building the wood wings.
As soon as I figure out how to keep my torch from burning through the edges of those two pieces of flat stock
I'll be back to let you know what NOT to do and what TO do.
 when a student is ready the instructor will appear.— Zen saying