Originally Posted by xjmarc (Post 2980636)

I am a booger weld expert so I'm going to keep my mouth shut on that but my question is have you measured the shackle to see if it'll fit inside that box channel?

Originally Posted by roninofako (Post 2980692)

You said you're running 6010...what technique are you using to lay down the bead? Whip and pause works best with 6010, and it is a deep penetrating electrode. Looks like you were trying to do a whip and pause (somewhat) than a weave pattern. I will be the one to say it: practice some more before committing to this project. Suspension can see some crazy forces, you want a good, solid bead laid down, especially on your root pass. If the outside of your welds look like that, imagine what they look like inside, probably full of inclusions...that will weaken the weld significantly. Not trying to burn you, just trying to help. You don't have a lot of material into the project yet, so find some scrap and practice, practice, practice...also, what amperage are you running at?

Originally Posted by stang65 (Post 2980703)

did you weld on the inside also?

Originally Posted by yorkee (Post 2982269)

I need to shave down the shackle bushing a few mm to fit.



I was about to post some pics of the finishing product, but you are right.
I don't have any confident driving the truck through potholes. Its not just supporting the 3800lb, its the force that pound on the joint when it hit the pothole. It's n times bigger than the stationary weight its supporting. Although it doesn't break, I feel like I am riding a time bomb. Like you said, I will probably practice, and I will do it again in clydesdale's style with several grade 8 bolt&nuts between two piece of metal as a fail safe.

Yes whip and pause and a weave pattern. I was using 100amp. I should've heat up the metal more and lower the amp?

I am going to skip the pictures of the finishing product since it's not a success. The next pics will probably a cut through the weld to see how bad it is.


Yes, but it's not worth mentioning. Its harder to lay good bead inside. I will consider its only a bit stronger than switches of tack weld. I thought they way I put the upper piece will have more metal bonding area compare to clydesdales. I think he has already thought it through.

Originally Posted by roninofako (Post 2982336)

Don't be embarrassed to put up photos, it shows us what you're doing, and we can advise you better. Your amps are a little high, but workable...usually run between 80-90 amps on 6010, so you're not too bad there...I would say in this case, just practice some more...try welding in different positions, too, the best way to get a good bead is time behind the hood. Keep us posted on your progress.

Originally Posted by JeepMN (Post 2982400)

https://www.youtube.com/user/welding...dtricks/videos

Watch every video. Multiple times. Soooo much information that has helped a lot of people out there just like you and I.

Weld on my friend.

Originally Posted by Hammered (Post 2983919)

If you can get some miller 80T+AC rod, it does a pretty nice job & cleans up well. Just a heads up for future projects.

Originally Posted by clydesdale (Post 2985389)

Thanks for the props Bud.
I'm glad our video helped you out.
I did weld every seam, inside and out. Maybe I should have showed more of that in the vid.
Boxing in the front and having a bolt through it made it a lot more ridged too.
Keep up the good work Pal.
I like how you started your own thread on this.
Subed.
And if your welds don't turn out, grind 'em out and do it again. There's no shame in that.

Originally Posted by shum8 (Post 2987220)

If I remember correctly it seems there used to be a 7018 AC rod on the market. When I had an AC buzz box I used some with great results. Also on this forum I have never heard mention of anyone using the local high school vocational welding classes to do any of their welding. I know here where I live the "trade School" as we call has an outstanding teacher and some of the kids are job ready welders way before they get out of high school. They are all the time doing projects and welding on things for people. Most of the time for free. Just a thought I had. Ive got 23 years exp at an electrical generating facility in maintenance. The old "its ugly as hell but strong" saying is bull crap. You have got to make every bead count. Esp when you are driving this thing down the highway. Not to seem critical but just encouraging everyone that welds on a component that is going to be on a vehicle to be extremely cautious.