Dexter Axle Hanger Bracket Weld Pattern Question

[Galen]

Hi Folks. Finally getting back to welding on the trailer frame.

Today I am welding on the Dexter Axle Hanger. I had thought to weld all the way around the hanger bracket. But the instructions say to weld on the ends and then three 2.5" welds on each side. You can see a picture of how this is done on Richard's site here:

http://www.richardflake.com/images/chas ... gtack4.jpg

My question is why not weld it along the entire length on the sides? Are they worried about heat distortion? I would rather have it all welded for strength and to keep moisture from between the hanger and the frame to prevent rusting. What would be the problem with that?

Thanks for your advice!

[KCStudly]

Warping is definitely an issue, but more than likely it is just a matter of what is required for strength vs. the cost of welding.

In industry welding is one of the more costly operations, relatively speaking, so designers are careful not to over specify.

On the trailer for TPCE I welded everything up fully to keep moisture out, but then spent some extra effort using special equipment to straighten it.

For another option, some good auto body seam sealer would fill that gap up just fine.

[Lonnie Mac]

As a designer, we always say "don't put lipstick on a pig".

[Galen]

... but then spent some extra effort using special equipment to straighten it.

Thanks. So, "special equipment" means a big hammer, right?

[eamarquardt]

As a designer, we always say "don't put lipstick on a pig".

Yeah but lipstick is cheap and the pigs seem to enjoy it.

My motto: Overkill in moderation.

Cheers,

Gus

[Galen]

Yah, I have decided to just weld it all up. It is cheaper than buying some body filler, and I can do it in short sections so it does not warp.

[KCStudly]

It will warp, it is just a question of how much and whether or not it is acceptable.

Somewhere deep in my build thread there are some pics of Karl and me setting up a jig table and using a hydraulic ram to straighten the frame rails on TPCE. Most would argue that it was not a necessary step, but we had the equipment and I feel it was worth the effort and should save a lot of trouble down the road.

[Galen]

Yes, the frame did warp a bit. But it would have warped even if I only welded it the amount suggested. And I see now that it even warped some in the front from the welds of the a-frame hitch attachment.

After I am done welding everything up I will straighten the frame.

[Bogo]

... but then spent some extra effort using special equipment to straighten it.

Thanks. So, "special equipment" means a big hammer, right?

Maybe. I've more often used a BIG torch and a pipe wrench. For some reason I've only run into twists from warping from excess heat. Any sort of bend can happen, but with experience it is possible to judge what may happen and make the welds in the right order to minimize or prevent any warping. If your parts can handle preheating, then that may help. Of course if you preheat it unevenly, that also can warp it...