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DIY Metal Ramp project

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  • DIY Metal Ramp project

    Been thinking of fabricating a sort of ramp and finally decided to make a metal ramp, a low angle metal ramp for that matter for my welding cart and 250 amp Mig so I can easily haul them up to my tool room say when work is done on a project for that day.
    Started gathering the materials in mind, what I have in stock and would just buy some added angle irons and probably some steel plates as I progress in a nearby metal store.









    Started cutting some angle irons then welded them up eith a stick welder to form a semi square configuration, about 58" X 60" for a start then braced them up with some scrap metal stock in the garage to keep them from moving. Height of the ramp is just about 6 1/2" more or less. Also sliced up both ends of the lower portion of the angle iron.
    CIGWELD Weldskill 250 amp Mig Welder
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    HITRONIC 300 Amp DC Inverter IGBT Welder
    YAMATO 300 amp AC Stick Welder
    YAMATO 200 amp DC Inverter IGBT Welder
    DeWALT Chopsaw
    HOBART and ESAB Welding Helmets


    cloned STIHLs

    MS 044 chainsaw
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  • #2











    Then added 4 pieces of 1 1/2" X 1/4" in the middle as support. By the way the main frame
    is 2 1/2" X 1/4" thick angle bars which I think will be enough to hold the weight of the welding cart or the MIG welder. At the lower end, I added another angle bar, the same size, 2 1/2" X 1/4" but made a semi cut on one portion then hammered it inside to form a sort of triangle to make that lower end stronger/stiffer.

    Then made a full weld of the entire length of 60" using 8 pcs of 7018 welding rods. Sorry but I missed out on taking pics on the procedure of this lower angle bar.
    Last edited by rosy; 02-23-2018, 09:53 PM.
    CIGWELD Weldskill 250 amp Mig Welder
    AHP Alpha-TIG 200X welder
    HITRONIC 300 Amp DC Inverter IGBT Welder
    YAMATO 300 amp AC Stick Welder
    YAMATO 200 amp DC Inverter IGBT Welder
    DeWALT Chopsaw
    HOBART and ESAB Welding Helmets


    cloned STIHLs

    MS 044 chainsaw
    MS 070 chainsaw

    Comment


    • #3
      Just some welds I made on the butt joints. Well not really the best looking weld beads
      out there but I made sure joints have been beveled and welded well with 7018 rods.

















      CIGWELD Weldskill 250 amp Mig Welder
      AHP Alpha-TIG 200X welder
      HITRONIC 300 Amp DC Inverter IGBT Welder
      YAMATO 300 amp AC Stick Welder
      YAMATO 200 amp DC Inverter IGBT Welder
      DeWALT Chopsaw
      HOBART and ESAB Welding Helmets


      cloned STIHLs

      MS 044 chainsaw
      MS 070 chainsaw

      Comment


      • #4









        Then with the remaining 1 1/2" angle iron, cut and made the supporting " shoes " to be
        welded under the main frame.
        CIGWELD Weldskill 250 amp Mig Welder
        AHP Alpha-TIG 200X welder
        HITRONIC 300 Amp DC Inverter IGBT Welder
        YAMATO 300 amp AC Stick Welder
        YAMATO 200 amp DC Inverter IGBT Welder
        DeWALT Chopsaw
        HOBART and ESAB Welding Helmets


        cloned STIHLs

        MS 044 chainsaw
        MS 070 chainsaw

        Comment


        • #5












          Here is the welded ramp frame with the supporting " shoes " welded and then followed with
          flap sanding all over, top and bottom after which painted it with three coats of Boysen
          Red Oxide to prevent it from further rusting..
          CIGWELD Weldskill 250 amp Mig Welder
          AHP Alpha-TIG 200X welder
          HITRONIC 300 Amp DC Inverter IGBT Welder
          YAMATO 300 amp AC Stick Welder
          YAMATO 200 amp DC Inverter IGBT Welder
          DeWALT Chopsaw
          HOBART and ESAB Welding Helmets


          cloned STIHLs

          MS 044 chainsaw
          MS 070 chainsaw

          Comment


          • #6



            Next, I purchased some 4 pcs. of pre cut steel plates measuring 18" X 48" .Then cut
            the fourth plate crosswise into 3 pcs of 10" each so I can just weld it to the remaining
            larger plates and fit the entire 58" width of the ramp.








            By the way the plates I purchased were only 2.0mm in thickness so I guess there is no
            need to bevel the sides to be welded. Decided for a butt joint, flap sanded the surface to
            be welded, removed traces of oil and mill scale. Then started welding by tacking the ends
            and applied an inch of beads in the center.

            At this point I decided to experiment on the three plate I will be welding since the plates are
            somehow thin and for sure there will be some distortion on one of the plates. With the first
            plate I will try to do longer distances between tacks then apply full welds and will see how
            the metal plates will react. Then on the second plate I will do tack welds with shorter
            distances the follow it up with full welds in between and again will observe some distortion
            if there will be any. And then on the last and third plate I will do more tack or stitch welds
            in a more shorter distances, starting at the edges perhaps then to the center and then to
            the left then right side letting each stitch weld applications cooling off. Will be observing
            again for distortion or warping. Welds will be applied on top and bottom sides, the top welds
            will be grinded almost flat but not so to the surface.









            CIGWELD Weldskill 250 amp Mig Welder
            AHP Alpha-TIG 200X welder
            HITRONIC 300 Amp DC Inverter IGBT Welder
            YAMATO 300 amp AC Stick Welder
            YAMATO 200 amp DC Inverter IGBT Welder
            DeWALT Chopsaw
            HOBART and ESAB Welding Helmets


            cloned STIHLs

            MS 044 chainsaw
            MS 070 chainsaw

            Comment


            • #7









              And there's me working and welding on the first metal plate !




              To be continued.........
              CIGWELD Weldskill 250 amp Mig Welder
              AHP Alpha-TIG 200X welder
              HITRONIC 300 Amp DC Inverter IGBT Welder
              YAMATO 300 amp AC Stick Welder
              YAMATO 200 amp DC Inverter IGBT Welder
              DeWALT Chopsaw
              HOBART and ESAB Welding Helmets


              cloned STIHLs

              MS 044 chainsaw
              MS 070 chainsaw

              Comment


              • #8





                This is the first metal plate that I welded. If you will notice I still did apply another tack
                in between the edge of the plate and the middle tack weld fearing that the space between
                the edge and the middle tack has still a wider distance. The top pic is the first left half and
                the lower pic is the second half.





                This is the full image that I welded using 4pcs of 3/32" 6013 rods at 85 amps. The metal
                plate has been secured properly on both edges with vise grips to minimize distortion but
                still the metal plate had some movement and got distorted. What I did was apply the first
                weld on the far left side then stopped on where a tack is applied, then went to the other far
                right of the plate. Then moved to the other inner left side where I stopped and applied another set of weld and stopped right in the middle, let it cool for a while then proceed to complete and finish the weld applications.

                Did the same procedure at the back side to counter act the distortion but it was not enough
                to bring the distorted metal to an almost flat surface. Well I suppose will just do some hammering to even out the surface.
                Last edited by rosy; 02-24-2018, 07:42 PM.
                CIGWELD Weldskill 250 amp Mig Welder
                AHP Alpha-TIG 200X welder
                HITRONIC 300 Amp DC Inverter IGBT Welder
                YAMATO 300 amp AC Stick Welder
                YAMATO 200 amp DC Inverter IGBT Welder
                DeWALT Chopsaw
                HOBART and ESAB Welding Helmets


                cloned STIHLs

                MS 044 chainsaw
                MS 070 chainsaw

                Comment


                • #9





                  This now is the second metal plate, again a butt joint. For the lower pic I started
                  applying several tack weld on the edges and some stitch welds on the inner portion.







                  On these two following pics, I did a different approach in applying my welds, first used
                  stitch welding on the spaces between the previous tacks letting it cool down a bit then
                  after finishing the first set, went again to apply more stitch welds in between the previous
                  applications, moving back and fort and letting them cool ones more. Did this procedure
                  too at the other side( back side ) and it did worked, distortion was relatively managed. .
                  CIGWELD Weldskill 250 amp Mig Welder
                  AHP Alpha-TIG 200X welder
                  HITRONIC 300 Amp DC Inverter IGBT Welder
                  YAMATO 300 amp AC Stick Welder
                  YAMATO 200 amp DC Inverter IGBT Welder
                  DeWALT Chopsaw
                  HOBART and ESAB Welding Helmets


                  cloned STIHLs

                  MS 044 chainsaw
                  MS 070 chainsaw

                  Comment


                  • #10


                    Then wire brushed the welds in preparation for the final application.










                    As I have already worked on the final applications and connected all the welds.
                    Here just cleaning again and removing the slags, same process was done on the
                    back side as mentioned before.
                    Last edited by rosy; 02-24-2018, 09:35 PM.
                    CIGWELD Weldskill 250 amp Mig Welder
                    AHP Alpha-TIG 200X welder
                    HITRONIC 300 Amp DC Inverter IGBT Welder
                    YAMATO 300 amp AC Stick Welder
                    YAMATO 200 amp DC Inverter IGBT Welder
                    DeWALT Chopsaw
                    HOBART and ESAB Welding Helmets


                    cloned STIHLs

                    MS 044 chainsaw
                    MS 070 chainsaw

                    Comment


                    • #11
                      Then for the third metal plate, again a simple butt joint. Cleaned the surface to be welded and just did the same procedure from the second plate applying welds from the edges then the middle portion. But here I was welding the top side and the back side one after the other. Tack welds were now a bit more closer with shorter distances..












                      Don't expect a well looking weld beads at the end coz these are several short stitch welds
                      connected together done on both sides to prevent metal warping. Well that is more of my
                      concern since anyway the top side welds will just be grinded off but not totally flashed to
                      the surface.

                      Anyway my findings with this procedure came out very positive, the metal joint
                      had no signs of warping. Applying the welds and flipping the metal plate after each weld on
                      both side countered act metal movement. Its kinda tedious and tiring since the metal plate is a bit heavy but it worked, I got a straight and flat surface.
                      CIGWELD Weldskill 250 amp Mig Welder
                      AHP Alpha-TIG 200X welder
                      HITRONIC 300 Amp DC Inverter IGBT Welder
                      YAMATO 300 amp AC Stick Welder
                      YAMATO 200 amp DC Inverter IGBT Welder
                      DeWALT Chopsaw
                      HOBART and ESAB Welding Helmets


                      cloned STIHLs

                      MS 044 chainsaw
                      MS 070 chainsaw

                      Comment


                      • #12



                        Any way before finishing the third plate I made a dry fit just to see how it will appear.
                        During this stage I added some strips of flat bars in between the plates, its 1 1/2" X 1/4
                        and 58" in length.
                        CIGWELD Weldskill 250 amp Mig Welder
                        AHP Alpha-TIG 200X welder
                        HITRONIC 300 Amp DC Inverter IGBT Welder
                        YAMATO 300 amp AC Stick Welder
                        YAMATO 200 amp DC Inverter IGBT Welder
                        DeWALT Chopsaw
                        HOBART and ESAB Welding Helmets


                        cloned STIHLs

                        MS 044 chainsaw
                        MS 070 chainsaw

                        Comment


                        • #13
                          Decided to clad the flat bars and so started cutting two strips of 1.6 mm thick
                          " checkered " stainless sheet/plate I have in stock, its 4 1/4" X 48", sort of short to
                          fill the entire flat bar strips so I will just cut some 10" of stainless sheet and just
                          connect and weld it to the 48" stainless strips.





                          CIGWELD Weldskill 250 amp Mig Welder
                          AHP Alpha-TIG 200X welder
                          HITRONIC 300 Amp DC Inverter IGBT Welder
                          YAMATO 300 amp AC Stick Welder
                          YAMATO 200 amp DC Inverter IGBT Welder
                          DeWALT Chopsaw
                          HOBART and ESAB Welding Helmets


                          cloned STIHLs

                          MS 044 chainsaw
                          MS 070 chainsaw

                          Comment


                          • #14








                            I hammered the sides to soften the edges and then welded it to the angle bars
                            using 3/32" Nihonweld stainless rods.

                            CIGWELD Weldskill 250 amp Mig Welder
                            AHP Alpha-TIG 200X welder
                            HITRONIC 300 Amp DC Inverter IGBT Welder
                            YAMATO 300 amp AC Stick Welder
                            YAMATO 200 amp DC Inverter IGBT Welder
                            DeWALT Chopsaw
                            HOBART and ESAB Welding Helmets


                            cloned STIHLs

                            MS 044 chainsaw
                            MS 070 chainsaw

                            Comment


                            • #15











                              The back of the metal plates has been painted with three coats of
                              BOYSEN Red Oxide. Not yet welded on the angle bar frame, I will install first the
                              main frame on its intended location then probably weld the plates or tap them
                              so it can easily be removed /dismantled just in case.

                              And so this is my first project for this year, started the works first week of Jan. then completed it a few weeks back, third week of Feb.
                              Last edited by rosy; 02-25-2018, 01:41 AM.
                              CIGWELD Weldskill 250 amp Mig Welder
                              AHP Alpha-TIG 200X welder
                              HITRONIC 300 Amp DC Inverter IGBT Welder
                              YAMATO 300 amp AC Stick Welder
                              YAMATO 200 amp DC Inverter IGBT Welder
                              DeWALT Chopsaw
                              HOBART and ESAB Welding Helmets


                              cloned STIHLs

                              MS 044 chainsaw
                              MS 070 chainsaw

                              Comment

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