Safety and workshop equipment 9

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1 Safety and workshop equipment 9 Whichever type of welding/cutting you practice, safety must be the priority. Using this equipment is dangerous, with potentially fatal consequences should something go wrong. Although each type of welding/cutting has its own safety requirements, there are some that are common to them all. Workshop environment Ensure the area is sufficiently lit Extra lighting is a good idea to ensure you re actually welding where you re supposed to! When looking through a shield or mask prior to striking an arc, it can be very difficult to see exactly where on the workpiece to start. WELDING GAS PROPERTIES GAS Acetylene Argon Carbon dioxide Helium Nitrogen Oxygen Propane ODOUR Ether Natural gas DENSITY Air COLOUR Many of the gases used in welding/cutting/heating processes are heavier than air, colourless and odourless. Ensure the area is not too hot or too cold Weldors stand for long periods of time without much movement because they need to maintain a steady hand position, which means body temperature can drop quickly in a workshop with insufficient heating. Conversely, in hot weather, because the weldor must remain fully clothed, the workshop can become unbearably hot. Keep it tidy Ensure the work area is clear, with no potential hazards lying around ready to trip up the unsuspecting welder hurrying across the workshop, carrying hot metal to the quenching tank. Don t leave combustible material (paper, cardboard etc.) lying around - when the red hot spatter hits the ground, it will shoot off in all directions! Electrical safety Be sure that the electrical system to which the welder/cutter is connected is in a good state of repair, and sufficiently protected from accidental short circuit or overload. Carry out periodic inspections to ensure all connections are secure and in good condition. Ensure the area is well ventilated When welding or cutting, many different types of gases may be released. Whether the gas is from the welding equipment or produced by something oxidizing on the surface of the workpiece, many of these gases are odourless, colourless, and highly poisonous. The inert shielding gases used by MIG and TIG welders displace oxygen around the area being welded, and if used 9 1

Chapter 9 You ll find most of your welding safety gear and clothing at your local welding supply store, such as helmets, leather protective wear, gloves and safety shields or goggles.

This can very quickly can cause loss of consciousness, as the gas not only denies the body oxygen, but also forces the oxygen being carried around the body to be expelled.

2 Chapter 9 You ll find most of your welding safety gear and clothing at your local welding supply store, such as helmets, leather protective wear, gloves and safety shields or goggles. in a confined space can build up and exclude oxygen from the immediate area. This can very quickly can cause loss of consciousness, as the gas not only denies the body oxygen, but also forces the oxygen being carried around the body to be expelled. The transition from awake to slumped over can take only a few seconds. If working in a confined area, let someone know you re there, and ask them to check on you now and then - you may not be able to rescue yourself. Also bear in mind that most of the gases used are more dense than air. Consequently, the gases can collect in the lower part of the work piece or workshop area eg. in the bottom of an inspection pit or water tank. Ideally, an exhaust extraction system should be used, but at the very least, ensure there is a flow of air around the workpiece and weldor. Noise Although the welding/cutting process itself is not excessively noisy, many processes associated with welding are, eg. grinding. Prolonged exposure to loud noises can cause permanent hearing damage, which can be easily prevented by taking a few seconds to put on ear defenders. welding area. If an assistant is helping by steadying the work piece etc. ensure they are as protected as the welder - simply shutting your eyes is not sufficient. Eyes and skin All welding/cutting processes produce lots of visible, ultraviolet and infrared light. Even momentary exposure to the radiation from arc light can cause serious damage to the eyes. Obviously, the person welding requires a welding shield/goggles or mask suitable for the task, but other people in the workshop, and any passers-by should be protected from danger by positioning screens around the This welding helmet offers full face and chin protection, and features a flip up welding lens. When you are setting up to weld, the helmet can be down on your head and you look through the clear lens, then flip down the dark lens just before welding. Some weldors find these better than fixed lenses where you have to shake your head to flip the whole helmet down. 9 2

Safety and workshop equipment This L-TEC helmet from ESAB, called the Liftorama, features a lift-up safety lens, and underneath a shatter-proof clear lens that can be used when grinding a weld.

The Scanorama helmet was designed for MIG and TIG-welding applications, with a large shade 5 filter disc surrounding the welding lens.

3 Safety and workshop equipment This L-TEC helmet from ESAB, called the Liftorama, features a lift-up safety lens, and underneath a shatter-proof clear lens that can be used when grinding a weld. Another L-TEC helmet, the Weldorama offers a clear sight plate above the welding lens, so the weldor can keep the helmet down, and then just shift his eyes to the dark lens when he is ready to weld. The Scanorama helmet was designed for MIG and TIG-welding applications, with a large shade 5 filter disc surrounding the welding lens. You can see most details through this area, but your skin is still protected from radiation. You look through the darker portion when welding. This Darth Vaderish design from ESAB is the Autorama 2000, one of a modern breed of welding helmet with an automatically-darkening lens. The lens is powered by solar cells, and turns dark as soon as the welding arc begins. These are considered by many weldors to be much easier to use than flipping a helmet up and down to set up each weld. 9 3

Weldors (and their assistants) should be fully clothed at all times, with no bare skin exposed.

4 Chapter 9 Daytona MIG offers a variety of modern safety helmets, and a special, clip-on lens (foreground) that attaches to your MIG gun. It allows you to set up a weld, then look through the lens when making spot-welds without the bother of a full helmet. The radiation from the arc can also quickly cause burns to the skin. Weldors (and their assistants) should be fully clothed at all times, with no bare skin exposed. Safety boots and leather gloves must be worn, sleeves must not be rolled up and tucked into the gloves - a red hot ball of spatter going up your sleeve when overhead welding is something you don t want to experience! For the same reason, ensure your trousers do not have turn-ups, and your shirt or jacket does not have pockets. Don t be tempted to work with your shirt open on hot days, hot spatter burns deep and can cause nasty infections. When chipping off slag from arc welding, always wear safety goggles. When struck with a chipping hammer, the slag can leap in any direction - it s also very hot, and as sharp as broken glass. Gas bottles These need to be stored in a secure area, and supported at all times to prevent them from falling over. They need to be protected from extremes of temperature, kept clean and regularly inspected. Pay particular attention to the condition of the hoses - as they age they will deteriorate and perish. Do not be tempted to carry out a temporary repair to the hose with tape etc. The consequences of an un-noticed leak are possibly catastrophic - renew the hoses. A good pair of leather welding gloves will last you for years, but if you are using oxy-acetylene equipment, keep an extraclean pair for use with this equipment. A spurt of oxygen on a dirty glove could cause combustion, so don t use these good gloves for handling hot or dirty parts. Equipment When it comes to equipment for working with metals, there s a lot more required than just a means of cutting metal and fusion-joining it. Many automotive enthusiasts are 9 4

Safety and workshop equipment From HTP is this Super Spark Guard welding blanket. It can take up to 1260 C, and can be used when working on a car to protect the window glass, dash or interior.

The heat-absorbing spoon can be used to back up butt welds or when filling holes in sheet metal. The welds will not stick to the copper.

Other than your welding/cutting equipment itself, the two main requirements for a good environment are the proper safety gear, particularly the goggles or helmet, and a clean, safe, well-designed

5 Safety and workshop equipment From HTP is this Super Spark Guard welding blanket. It can take up to 1260 C, and can be used when working on a car to protect the window glass, dash or interior. It measures 1.0 metre by 1.2 metres. A very useful tool when welding on thin materials such as newer-car body metal is a copper spoon. The heat-absorbing spoon can be used to back up butt welds or when filling holes in sheet metal. The welds will not stick to the copper. tool addicts to begin with and welding just adds another dimension to the want list. Other than your welding/cutting equipment itself, the two main requirements for a good environment are the proper safety gear, particularly the goggles or helmet, and a clean, safe, well-designed welding work area or table. As you ll see, there s a wide variety of helmets available. Choose one that you are comfortable with and that meets your budget. You may have got a basic helmet with your welding machine, and you can use that until you save up for one of the more advanced models. Other personal safety equipment would include steel-toed industrial safety shoes (available at most shoe shops), good leather gloves, fire-resistant long-sleeved shirts or, if you are arc-welding, a leather welding jacket and/or apron. A clean, safe welding table set-up is of paramount importance. While you are learning, there will be a lot more sparks and slag generated than when you are advanced, and your welding table should be heavy steel, positioned well away from all stored flammable material and with a clear area underneath for any sparks or molten slag to be safely contained without having them scooting across the A clean, safe welding table area promotes good work. Your home workshop won t need a steel-plate table this big, but note how uncluttered and organised things are here in a professional workshop. A rack under the table holds all the C-clamps. 9 5

Chapter 9 workshop or lodging on top of your shoes. For metal cutting, you need a good grate set-up as pictured in Chapter 3.

Do not just cover your old wooden work bench with a piece of sheet metal and call it a welding table. Invest in a piece of plate from a scrap yard.

the workshop. Also, you must have proper fire extinguishers on hand, that can put out all kinds of fires.

6 Chapter 9 workshop or lodging on top of your shoes. For metal cutting, you need a good grate set-up as pictured in Chapter 3. You will also need some firebricks, which are helpful to practise welds on because the work won t stick to them. Do not just cover your old wooden work bench with a piece of sheet metal and call it a welding table. Invest in a piece of plate from a scrap yard. When you put a lot of heat into welding projects on a tin-covered wooden surface, enough heat can go through the metal to start the wood smouldering, perhaps even starting a fire after you have left the workshop. Also, you must have proper fire extinguishers on hand, that can put out all kinds of fires. Much of the work of sizing and joining metals for home workshop projects will involve tools you already have, such as a drill press, grinders and sanders, clamps, measuring equipment, squares and levels. A common hacksaw can be used to sever lengths of material but can be tedious on heavier-wall stock. Sheet metal can be cut with tin-snips, manual or electric nibblers, or a plasma cutter. Many of the tools shown here are special-purpose tools that you may not have already, and which perform special functions that relate to improving welding work or holding materials to be welded. All of them are useful when the time comes. We all wish we could just put one of each in our home garage, but you may have to collect them over the years as your projects get more involved. We also show here some tools and equipment that were made by fabricators and customisers for their own use. These are typical of projects you can do once you have practised your welding skills, and some represent considerable involvement, though on the part of someone who has already been there. Some workshops have a dedicated grinder, like this Clarke 6-inch Bench Grinder, for sharpening tungstens. If you get into a racing car project, you might invest in one of these tubing notchers. It fits in your drill press and allows precise fish-mouthing of tubing via a captive hole saw. Eastwood offers this magnetic quick-clamp which functions to hold parts in alignment at various angles for tack-welding. 9 6

Safety and workshop equipment This unique spot-welding gun for sheet-metal work has a power lead that clamps

Use the trigger to make the electrode touch the work, pull up for 5 seconds, then pull all the way to break

It cuts fast and straight and is very helpful in cutting tubing at angles and other chores associated with

7 Safety and workshop equipment This unique spot-welding gun for sheet-metal work has a power lead that clamps into the electrode holder of your arc welder. Use the trigger to make the electrode touch the work, pull up for 5 seconds, then pull all the way to break the arc. One of the handiest workshop tools we have ever used is this portable bandsaw. It cuts fast and straight and is very helpful in cutting tubing at angles and other chores associated with welding projects. A bench-mounted circular sawing machine is very fast and secure when it comes to cutting large amounts of tubing. The work may be held in a moveable vice, so that angle cuts can be made. 9 7

Chapter 9 Other kinds of metal-cutting power saws include this type,

to cut out factory spot welds to remove panels for renewal.

8 Chapter 9 Other kinds of metal-cutting power saws include this type, which uses a bi-metallic toothed blade, here being used to cut clean through aluminium tubing. In car bodywork, a tool like this can be used in your electric drill to cut out factory spot welds to remove panels for renewal. This is a similar tool for removing spot welds which features a hex-sided drive end, so it can t slip in your drill chuck. 9 8

Safety and workshop equipment This electrode rack is made from a rolling platform holding 15 plastic plumbing pipes with

The tubes keep the rods clean and dry. You never know when you ll find something that comes in handy in the workshop.

It s dead flat and cannot warp, and has mounting holes in it for clamping work to it.

9 Safety and workshop equipment This electrode rack is made from a rolling platform holding 15 plastic plumbing pipes with caps, each marked for the size and type of electrode. A bungee cord holds them in the rack. The tubes keep the rods clean and dry. You never know when you ll find something that comes in handy in the workshop. This huge and hefty round plate was found at a metal yard and bought at the per-pound price. It s dead flat and cannot warp, and has mounting holes in it for clamping work to it. If you plan to do any ornamental iron work or make a lot of brackets, a bending tool like this is very handy. It can bend solid round, square or hex stock, as well as bend round tubing and flat stock into repeatable shapes. 9 9

Chapter 9 A disc sander with at least 500 watts is very handy around the workshop for squaring

A belt-sander can get deep into corners and places where normal sanders and grinders can t reach.

Ideally, you would have both a disc sander and belt sander for a variety of metal finishing needs.

10 Chapter 9 A disc sander with at least 500 watts is very handy around the workshop for squaring edges of flamecut parts, and taking sharp edges and corners off work. A belt-sander can get deep into corners and places where normal sanders and grinders can t reach. The belt guide rotates 160 degrees, and the sander uses 10 mm belts. Ideally, you would have both a disc sander and belt sander for a variety of metal finishing needs. There are combination units, but beware of under-powered sanders. When you put the rough edge of a 10 mm plate up there to sand, they stall easily. 9 10

Safety and workshop equipment This Clarke Air Sander is perfect for a swirl-free finish.

your fingers. No tool is needed. They have a range of up to 6.0 mm for thickness, and fit a 3.

Nothing beats the original Cleco clamps and pliers for testassembling sheet-metal parts.

In blind holes you insert the fastener with the pliers and the two parts are held together,

11 Safety and workshop equipment This Clarke Air Sander is perfect for a swirl-free finish. For small jobs, Eastwood offers these little Cleco-type panel holders that you operate with your fingers. No tool is needed. They have a range of up to 6.0 mm for thickness, and fit a 3.0 mm hole. Nothing beats the original Cleco clamps and pliers for testassembling sheet-metal parts. Originally developed for aircraft use, these operate like reusable, temporary rivets. In blind holes you insert the fastener with the pliers and the two parts are held together, but come apart easily with the pliers again. This Air Speed Saw from SIP is good for car body work, and for cutting through manifolds, springs, bolts, etc. It can operate at 2200 strokes per minute. 9 11

Chapter 9 When you want to spot-weld sheet-metal panels that didn t have them

pull out creases and dents by drilling holes and using slide hammers that

Small-headed copper-plated studs are inserted into the magnetic head of the

12 Chapter 9 When you want to spot-weld sheet-metal panels that didn t have them originally, like new parts or repair panels you have made, a manual flange punch like this is a real help. An air-powered nibbler is a fast, clean way to cut sheet metal up to 2.5 mm in steel or 3.5 mm in aluminium. It will follow a pattern or cutline very closely, and you control the speed with the throttle. The SIP Spotter Kit is a great boon to body repairers, who used to have to pull out creases and dents by drilling holes and using slide hammers that distorted the metal even further. Small-headed copper-plated studs are inserted into the magnetic head of the stud setter. On a dented area that has been ground to clean metal, the tool is pushed in contact with the metal and the trigger is pulled for a half-second. The studs are spot-welded in place, and a special slide hammer is used to pull out the dent or crease. Studs hold 2000 N of pull. 9 12

Safety and workshop equipment On this dent, the first three studs pulled out the bulk of the damage, and

Note how the first three studs have been clipped off with cutting pliers.

holes left to fill in, as with conventional methods.

13 Safety and workshop equipment On this dent, the first three studs pulled out the bulk of the damage, and two more are in place to pull the last bit out. Note how the first three studs have been clipped off with cutting pliers. After the pulling, the stud heads are easily ground off without distorting the metal, and there are no holes left to fill in, as with conventional methods. Visit most customising workshops, fabrication workshops and racing car facilities, and you ll find that a lot of the workshop equipment they have is home-made. These are the kinds of things you ll be able to do once you have welding and cutting equipment. 9 13

Chapter 9 A simple steel materials rack like this is great for keeping tubing, bar stock and flat stock out of

In front of this one is an electric, automatic bandsaw great for making unattended cuts.

Watch your newspapers for industrial auctions and workshop foreclosures.

This fixture for making up a hot-rod four-link rod is made from short pieces of angle-iron and a length of

14 Chapter 9 A simple steel materials rack like this is great for keeping tubing, bar stock and flat stock out of your way, and is easily constructed. In front of this one is an electric, automatic bandsaw great for making unattended cuts. This one was purchased inexpensively at a tool auction. Watch your newspapers for industrial auctions and workshop foreclosures. Leftover pieces of tubing and other stock should be saved in a barrel. You never know when you need a short piece. This fixture for making up a hot-rod four-link rod is made from short pieces of angle-iron and a length of rectangular tubing. An old wheel rim, a length of round pipe and a piece of scrap plate are combined with welding to make a perfect small welding table or mounting for a grinder or sander. Ideal for holding small brackets onto tubing for tacking are these magnetic blocks, available at most welding supply centres. 9 14

Safety and workshop equipment SIP and other companies offer these strong magnetic holders that can secure two pieces

Tack the parts then move the magnets to the next joint.

A portable bandsaw is another very useful tool in the busy workshop.

This one is an SIP 110 mm metalcutting bandsaw; it has three speeds for metal, plastic or wood, and can operate in a

15 Safety and workshop equipment SIP and other companies offer these strong magnetic holders that can secure two pieces of tubing for angles of 45 degrees, 90 degrees, and 135 degrees. Tack the parts then move the magnets to the next joint. Another angle fixture from SIP is this type, which clamps the two parts at a perfect 90 degree angle for tack-welding. A portable bandsaw is another very useful tool in the busy workshop. They are ideal for cutting any lengths of tubing or box section you may require. This one is an SIP 110 mm metalcutting bandsaw; it has three speeds for metal, plastic or wood, and can operate in a horizontal or vertical position. Daytona MIG sells this handy spot-sandblaster. It is useful for cleaning paint and rust away from a spot you have to weld, like a recess where a regular sander won t reach. Threequarters of the blasting medium is returned to the gun, so it won t make your workshop a sandpit. 9 15

Chapter 9 This typical workshop MIG welder from Mac Tools has a shelf at

The latest welding helmets feature automatic lens adjustment (from light

Modern helmets feature adjustable shading protection and adjustable

16 Chapter 9 This typical workshop MIG welder from Mac Tools has a shelf at the rear to securely store the Argonshield bottle. The latest welding helmets feature automatic lens adjustment (from light to dark in sec), and neck protection. Modern helmets feature adjustable shading protection and adjustable sensitivity. This tool produces a stepped flange at the edge of a repair panel. So that after lap welding the panels will be flush. 9 16

Safety and workshop equipment A bench guillotine like

17 Safety and workshop equipment A bench guillotine like this will cut steel up to 4 mm and aluminium up to 6 mm thick. The SIP Migmate Turbo 150 DP, can be used for normal or gasless MIG welding. The MIG wire for gasless welding has the shielding material in its core. MIG wire reels are available in many different sizes. 9 17

18 Chapter 9 Oxygen cylinder dual regulator. This dual-purpose TIG machine is also capable of arc welding. If you plan to fabricate using tube, an hydraulic tube bender is invaluable. 9 18

19 Safety and workshop equipment The Inverter 175 is capable of Arc and TIG welding, producing a DC voltage for precision, smooth results. For the beginner, the Wizarc 100 Arc welding kit is ideal - capable of welding mild steel up to 5 mm thick. 9 19

Chapter 9 A leather apron will protect you

20 Chapter 9 A leather apron will protect you and your overalls from hot spatter. Autoplus 249 Turbo DP from SIP is designed for automotive bodyshop use - capable of welding in MIG or Gasless MIG modes. A selection of welding clamps are essential in the workshop. 9 20

Hi, and thanks for downloading my free report that is sure to give you many ideas for setting up your welding shop.

Hi, and thanks for downloading my free report that is sure to give you many ideas for setting up your welding shop. There s a good chance you re a beginner to welding if you ve downloaded this report,