Welding - need some direction from scratch builders.

[Sonex1542]

Folks,

At the stage where I need some welded parts. I'd love to be able to afford a good welder, but that's just not gonna happen. I do have a HF welder, have welded a few things around the house, and its done a decent job, also have a professional welder lined up at 25/hr.

I'm thinking of doing some of the following, I know what the best solution is, but what's an acceptable compromise?

1. Cut and tack the parts with the HF welder and give it to the pro to finish?
2. Can I use the HF welder for any pieces. Such as control push rods, control stick assembly, etc? I Would not weld the elevator bell assembly, too critical a component, but can use option 1 on that?

Seems easier to tack up the parts as they would fit, then weld, as opposed to the other way around. Tail skid piece was a good example, I didn't see that as a bad piece to weld myself, and it came out pretty good.

So, what suggestions do you have that are reasonable please...

[Bryan Cotton]

Tack welding then bringing it to the pro is a very reasonable way to go. On my scratch built and restoration projects I did my own welding with gas. There is debate on the suitability of MIG welds for chromoly aircraft structure. To counter that I believe ACA makes new Citabrias using wire feed. A pushrod is critical too. If that weld breaks you are having a bad day.

[fastj22]

I'm a welder in training. Started with flux core gas less MIG, then gas MIG on numerous farm and car projects. Gas MIG is much better. The HF you have is probably only flux core. It works well, but is best for farm repairs and not detail work. Gas MIG just is cleaner and more controllable but requires some skill and experience. TIG is best for this but requires a lot of skill and experience.
I am building a Pietenpol with steel tube fuselage. I attended the TIG and gas welding classes at AirVenture and choose to do gas for the Piet.
I will tack the fuselage with the MIG and then weld the joints using the gas. This will relieve the stresses that TIG/MIG leave on the joint. Turns out, many TIG/MIG welders re-heat the joints up to a glow with a gas welder after using the TIG/MIG to relax the joint anyways. So you need both anyways.

You are best off tack welding your pieces with the HF and taking them to a pro for final welding. Or invest in the time and equipment to do it properly. Then of course have it inspected by someone who knows what to look for. My goal is to learn to weld properly and do my entire Pietenpol fuselage myself. If I can't get the swing of gas welding, I'll just tack it and take it to someone.

[Sonex1542]

Thanks, I'll just tack things together and go with te guy I have lined up, saving a few bucks and rushing isn't worth it. Best of all he's a gas/oil guy, TIG/MIG/Gas welder, lots of years and lots of chromoly work.

Thanks.

[Bryan Cotton]

Most of the hours are the setup of the parts, so your use of the pro will be very efficient.

John,
If I learned to gas weld I bet you can too. Invest in some tubes to turn into scrap. I welded and cut up a zillion T fittings in the beginning. At first it was hopeless, then it progressed to terrible, and once I got to bad I knew I could do it. Kept welding and moved up to poor, then ok, then good.

Gas welding is one of the most therapeutic hands on activities I have done. It is hypnotic and you will also see it when you close your eyes for the night. After I finish the Waiex and hummelbird, a scratch Skybolt is next for me.

[ldmill]

I'm selling my dear old Pietenpol and just started on the fuselage of a WagAero Sport Cruiser in my basement this year. Best thing I did was to attend the Sport Air welding workshop in Osh last winter. Very small class over a weekend with a certified aircraft welder as the instructor.

Lorin
N81YX