Working with metal

[zoll]

Hi all,

I've finished my prototype feather made from wood.... I'd perfer to make my next feather from metal rather then plastic but have no experience what so ever in metal work. Is it feasible to build my next bot from metal and what tools would i need. Im guessing id need a welder, which from a quick look would cost around £250 + gas. Any thoughts?

[typhoon_driver]

Re: Working with metal

You don't need a welder at all to work with metal.

Tools that are useful to have when working with metal,

- hacksaw
- Set of HSS drill bits
- scribe
- angle grinder (if cutting steel)
- pillar drill for accuracy when drilling

Those are just the ones that jump to mind

You can get away with bolting everything together rather than welding. Welding in itself is a whole other process but I believe it was Mario that put it to me like this some years ago, a bolt is stronger than a bad weld but a good weld is stronger than a bolt. Basically it takes some time to get good at welding and in the mean time bolting everything will do the job fine.

Use pieces of angle steel (say 20mm by 20mm by 2mm thick), drill holes and bolt as required. I'd recommend using M6 bolts for bolting everything together. Buy em in bulk off ebay or screwfix.

[billy breach]

Re: Working with metal

Why don't you try working with hdpe. Thats strong and very easy to work with

[typhoon_driver]

Re: Working with metal

use nylon for structural components and HDPE for armour. HDPE is no good for structural parts as it's soft and deforms

[billy breach]

Re: Working with metal

It would be lighter as well I'd think.

[zoll]

Re: Working with metal

You don't need a welder at all to work with metal.
Welding in itself is a whole other process but I believe it was Mario that put it to me like this some years ago, a bolt is stronger than a bad weld but a good weld is stronger than a bolt. Basically it takes some time to get good at welding and in the mean time bolting everything will do the job fine.

Thanks for the quick responses, my goal was eventually to build a heavy weight which from what I gather are usually metal in constructions. Hence I was looking to start doing some 'bad welds' on a feather and build up to good welds on a heavy. But do people think I would be able to start learning to weld from scratch and how much would it cost to do so? Also what type of welding do people use, arc or mig?

[typhoon_driver]

Re: Working with metal

I started off welding up steel a number of years ago with a cheap arc welder I bought for around 35 quid from macro during a sale. It took me a while practicing and reading various articles. I have since sold off that welder to Jamie and bought myself an all singing, all dancing TIG welder. It not only TIG welds but arc welds as well.

A MIG can be a nice investment but you don't want to go for a cheap one and don't go for a gasless one. Buying argon gas for the hobby market can be a real pain and very expensive. Usually companies will want a monthly fee whilst you have the cylinder and chances are that you wouldn't be using it on a regular basis. I found a company that takes a deposit upfront and then charges for refills as I go. But it is a lot more expensive doing it this way initially.

To sum up, look to buy a cheap as chips arc welder. It will allow you weld up steel box section, steel and hardox plate.

MOST IMPORTANTLY!!!! Make sure you also buy suitable safety gear. I would highly recommend a decent pair of welding gloves (five quid on ebay), an auto darkening mask (from around 25 quid on ebay) and wear long sleeves and cover all your skin when welding. Never look directly into a weld, you can damage your eyesight and if you have exposed skin then it will burn.....I learned these the hard way

[maddox10]

Re: Working with metal

A cheap arcwelder , capable of 120 to 140 amps, costs in budget friendly shops around £65. And comes most of the time with a small pack of 2.5mm electrodes, a cheap welders visor and a cheap chiphammer and wirebrush.

With this you can weld most mild steel applications in the robots.
Stainless or hardox is not out of the question , even with good results. But it will take a lot of practice.

It's also the cheapest welding you can do. A MIG or TIG needs argon and specialised welding wire.
A gasless mig, that needs the expensive filled wire. Oxy-Acy is very consuming in gasses, and those ain't cheap either.

One word of advice, when welding, make sure the clothing you wear is pure cotton, wool, or treaded for the purpose. You don't want flaming and/or melting nylon, polyprop or simular clothing..