Bevelling Steel Pieces for Welding

[MinnesotaDaveChalmers]

I have a project with many pieces of 1/4" thick -1/2" thick that will be butt and fillet welded. Normally I just use the 4 1/2" amd or/ 9" angle grinders to create the bevel. Creates a lot of fine dust and sparks. Is there a better process you guys use? I have a drill press with a milling vise so thought that might lend itself to doing the task more efficiently and have chips instead of dust and sparks that start fires. I am not a machinist by any stretch although I have use end mills in the DP for milling grooves. Back in my pipefitter days some fab shops had a machine with a lathe bi for bevelling pipe, that was slick but expensive.

Bring on any ideas you have.

Ron

Chop saw, band saw, plasma or torch are my choices - cutting the angle while cutting the piece to length.

If the piece is already cut to length, I like to start torch or plasma on the cut edge and blow back towards the main thickness.
That way I can concentrate on making a nice straight "land" on the thin edge.

One note: when grinding, a bevel on both sides of a piece takes off half as much material than a one sided bevel (if both methods are a knife edge and at the same included angel)
- half the work is always better in my book

 

[CalG]

OK.
A show of hands.

Who would use a band saw on 1/4 inch thickness material?

Not I.


Who would use a band saw on 1/2 inch thick material?

Maybe I would . depending on how well the parts "fit" onto the saw. (Marvel 6X12)

 

[Shield Arc]

OK.
A show of hands.

Who would use a band saw on 1/4 inch thickness material?

I would.

 

[MinnesotaDaveChalmers]

I would.

+1, me too

I look like a good welder when all my pieces fit excellent

 

[kencunningham]

I have a millwaukee metal cutting circular saw that can be set to produce bevel cuts. I havent used it enough to comment on how long a blade will last, they are about 40-50 dollars for the millwaukee blades. It will make the cuts much faster than a band saw. It cuts 1/4 inch just about as fast as cutting plywood, although it will cut the 1/2, you may find it wears the blade out faster. I found mine on ebay for 270 dollars with free shipping, that was too good to pass up. This is assuming you havent cut the pieces yet.

 

[Shield Arc]

I look like a good welder when all my pieces fit excellent

I've come to the conclusion, nothing will make my welds look good!

 

[MinnesotaDaveChalmers]

I've come to the conclusion, nothing will make my welds look good!

Stop using such a high quality camera - too much detail :laughing:

Use a blurry cheap one like mine, take the pic from 2 feet away, and just call all the welds good

 

[Tractor Seabee]

Thanks for all the good responses. They all have their place one way or another. Most of the pieces I need to do are 2 X 2 X 1/4 square tube and 2-6 inch X 1/2 flat bar; for a 3P hitch frame for a big vertical/horizontal log splitter. 4" cylinder with 24" stroke.

I am going to choose the band saw routine. I have all the pieces square cut already using the band saw, Just set the pieces at a 30 degree angle and turn it on, go do something else while it is cutting. By square cutting first I get a good land at the bottom. I hate having all the grinding dust down my shirt and flying all over.

Shield Arc, I lost your address. I have always been a hack welder, top pass is not like auto welders; but, I never had a problem passing certification back in the old days. That is why I have a good sharp 12" file and a grinder. I am getting ready for a vacation till the 30th. I will plan to come visit early July. This project will set till I get back.

I might try a cut off blade in an old miter box saw if I can find a way to keep the grinding dust out of the motor. Problem with the 14" chop saw (which I have) is they are not set up for miter cuts. Need to look at making a solution to that problem. It cuts real fast and throws the grindings away from the operator.

Ron

 

[kennyd]

Milling in most drill drill press's is very dangerous, the shallow taper used to hold the chuck on is not meant to handle side loading and it could fly off. Bailiegh Industrial makes some cool beveling machines, but they start at $700 and go WAY from there, some cool videos on YouTube on them if you search.

 

[Shield Arc]

I will plan to come visit early July. This project will set till I get back.

Ron if you have a lot of welding, bring your project here, and you can use my wire feeder.