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Date:  5-13-2017
Number of Hours:  7.00
Manual Reference:  
Brief Description:  Fab Anchor Brackets

Plans:

1. Finish the hub caps, clean & primer.

Status: Incomplete. Ran out of time working the torsion arms..

2. Create the brake anchor bracket components, weld together.

Status. Incomplete. I was able to complete one of the two internal anchor brackets. This turned out to be very difficult. My tools were inadequate and I did not have good welding results. I also am still learning how to weld. The net outcome is that it took all day to create one torque arm.

The component parts were cut from some 1 1/2" 4130 tube stock and strap. I used a sander to true the bar surfaces flush to a length of 1.25 inches. This dimension, after some trial and error, turned out to provide adequate clearance from the bolt heads in the drum when installed.

I was using a H.F. flux wire welder. I encountered two significant problems. First the spool of wire would tangle after a short time. This was due to the spool tension nut loosening as it unwound. A temporary fix was to simply remove it and hand thread a length of wire long enough to make some progress. I will fix this later by installing a stop nut to prevent the tension nut from loosening. The second problem is that my face shield was too strong. I simply could not see the weld line or pool as I worked. Basically I was welding almost blind. I have ordered a different set of goggles from Amazon with a #9 filter. We will see if that helps. The consensus on-line is that it would be better.

The part came out OK but I think I can do better. I am unhappy that the metal shifted slightly during fab. I also had a small burn through. I am hoping that the next attempt will be easier and go faster. At any rate my welding improved toward the end. I found that I had better results by holding the nozzle slightly off parallel to the part. That prevented the wire from sticking repeatedly.

We will call this a practice part. It looked much worse before I cleaned it up with a Dremel tool.
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Anchor Bracket Parts

Anchor Bracket Parts

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Welded Anchor Bracket

Welded Anchor Bracket

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Finished Anchor Bracket

Finished Anchor Bracket

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