Plug or weld open skeleton tubes?

[Ted+Teresa]

Hello! I bought Tony Latham's book, and am getting ready to weld together a 5 X 8 skeleton for our tiny trailer build.
I am going to use 2 X 2 X 1\8" metal for the frame. I am going to adjust the diagram for the shorter length.

I plan on using mitered corners for the 5 X 8 platform, creating a closed box.

I have two questions:

1) What is the best way to close the three holes at the rear of the 2 X 2, that attach to the tongue?


2) How do you figure the angle to cut the two pieces that join to the tongue? And what did you use to cut them with?


Ted

[David H.]

I would simply weld caps on the ends of the tube ( and grind them clean) before attaching to frame. To lay out the angles in front, lay out on table or ground. Cut with a zip blade on grinder

[tony.latham]

T&T:

I cut the A-frame tongue pieces (at the rear) at 90º and plugged with plastic.

For the front, I put them under the 90º piece, marked them, and then cut with an angle grinder using a cut-off wheel.

If the angle would help, I can probably pull up Sketchup and figure it out for you.



Tony

[halfdome, Danny]

One of these would be helpful right on the drawing. Danny


https://www.youtube.com/watch?v=MUgtW3KDds8

[Ted+Teresa]

Thank you for your responses!

I have not tried cutting with a grinder, and will practice before implementing. Worst case, I will head to a local shop and use their equipment.

I also need to build it (or find one already finished) in Sketchup, to confirm the lengths.

[tony.latham]

I have not tried cutting with a grinder,

Ted:

They are a special wheel:

https://www.amazon.com/DEWALT-DW8062B5-0-045-Inch-Stainless-Cutting/dp/B005B8LZCI/ref=sr_1_5?crid=8YSA71P8XCCT&dchild=1&keywords=grinder+cut+off+wheels+4+1+2+inch&qid=1613431659&s=hi&sprefix=grinder+cut+off+wh%2Ctools%2C221&sr=1-5

This guy is a little slow getting to the cutting part:



Tony

[Ted+Teresa]

Awesome. Thanks for that video!

I have been working with Sketchup Make:





I will figure out where the axle goes tomorrow...

[PCO6]

To each his own but I would highly recommend that you not remove the guard from your grinder.

[halfdome, Danny]

To each his own but I would highly recommend that you not remove the guard from your grinder.

For a lot less $ than a trip to the doctor, you could buy a metal chop saw and a face shield.
I'm not a Harbor Freight fan but they have one for about $50.
My metal chop saw has a clamp for holding the metal which is a safer way to cut metal.
When I need an angle more than 45 degrees I'll make a wood block ( on a wood chop saw)with an angle to make the desired angle, like 30 deg to make a 60 deg angle against the metal chop saw fence at 90 degrees.
Danny

[working on it]

To each his own but I would highly recommend that you not remove the guard from your grinder.

* I once had a cut-off disc explode on me at work...it was the only disc available, the grinder guard had been removed and lost (by co-workers), and I needed to use it anyway in a hurry. Luckily, I was using a full-face shield (there were many in the shop), so I received no injury.

* At home, I always use eye protection, and my grinders (one dedicated as a cut-off device, the other as a "grinder" only) both retain their guards. Plus, whenever the cut-off disc shows any chipping or signs of falling apart, I change to a new disc. I prefer Diablo's...bought three at a time.

[PCO6]

To each his own but I would highly recommend that you not remove the guard from your grinder.

* I once had a cut-off disc explode on me at work...it was the only disc available, the grinder guard had been removed and lost (by co-workers), and I needed to use it anyway in a hurry. Luckily, I was using a full-face shield (there were many in the shop), so I received no injury.

* At home, I always use eye protection, and my grinders (one dedicated as a cut-off device, the other as a "grinder" only) both retain their guards. Plus, whenever the cut-off disc shows any chipping or signs of falling apart, I change to a new disc. I prefer Diablo's...bought three at a time.

Good comment. Glad your experience wasn't worse. I'm with you. With a few exceptions I usually wear a Uvex Bionic face shield.

I saw the above YouTube video a few years ago before he decided to turn off the comments. I believe it came up on The Garage Journal Forum (might have been another one). Several pictures of disc accidents were provided and they were scary. One guy had a disc cut into his cheek where it stayed until he got to the hospital. The comments on the forum and the YouTube video were scathing. He was basically ripped a new one for his lack of safety. In the end he told everyone to take a hike and then turned the comments off.

[swoody126]

as for the angle ... this aint rocket surgery and the angle doesn't have to be specific

as in yout drawings lay out your pieces on top of one another and w/ a piece of thin posterboard under them simply trace your angle for transfer to the metal parts

this angle will be the same for all 4 cuts

just make sure the resulting lengths of the 2 diagonal braces are the same and that they come out in the same places on the sides of the tongue and body

no one butt you know where you wanted them and and a chigger whisker's difference between your drawing and the finished product will never be known nor will it matter structurally

if you are unsure of capping the aft ends of the diagonal braces cut an oversized piece of plate and extend the cap up the side of the frame a hair for added strength at that point

one thing i have done where the braces meet the fwd end of the tongue is to cut n weld a decorative gusset(arrow head shape) on top of that junction which can hide a lot of err...

it can even have a thru eyebolt coming up out of it "designed" for canoe lashing etc

horror fright frequently puts their house brand angle grinders on sale for $12± which could give you a dedicated cut off tool

the Diablo discs are worth the $$

and YES those guards are there for a reason

as mentioned above SAFETY EYEWEAR IS A MUST and you can't have too much of it

i wear a full face shield over my OSHA quality prescription lenses

the PPE in this case are way cheaper than just one trip to the eye ER(no need to ask how i know)

CARRY ON

sw

[BigDave_185]

To each his own but I would highly recommend that you not remove the guard from your grinder.

* I once had a cut-off disc explode on me at work...it was the only disc available, the grinder guard had been removed and lost (by co-workers), and I needed to use it anyway in a hurry. Luckily, I was using a full-face shield (there were many in the shop), so I received no injury.

* At home, I always use eye protection, and my grinders (one dedicated as a cut-off device, the other as a "grinder" only) both retain their guards. Plus, whenever the cut-off disc shows any chipping or signs of falling apart, I change to a new disc. I prefer Diablo's...bought three at a time.

Funny you say that. Had one explode on me Sunday and tear into my stomach, didn’t go through the short but I can for sure say it hurts a lot!

Not to mention the infection possible from the rusty metal I was cutting that is/was imbedded in my gut


Sent from my iPhone using Tapatalk

[twisted lines]

I like them capped.
The little cut off wheel's! Go right to the bone

[Ted+Teresa]

I agree with the safety conscious posts!! I will NOT be cutting without the guard, and will ALWAYS secure my work.
The video was great for me to see what to expect, having never used a grinder for cutting.
I am considering the $50 chop saw...
Also, there is a local shop where I can make cuts for $20, but scheduling might be difficult.

Thank you for your concerns!