One Notch, One Weld...Progress

Good fit-up is critical for quality, structural weldments. I used a 18V Makita drill and a Woodward Fab SP notcher. Makita makes a tough drill, 1st gear on that little tyke got a work out but powered through it all! I went through 3 Lenox 1.75" hole saws. Together with plenty of dark, sulfur-base thread cutting oil, I slowly worked my way through notching and welding everything. Again, the Millermatic makes excellent welds. I must have lost a few pounds of water each day...full pants, jacket, helmet, gloves, and a fun steel box to work in meant many hot evenings. But taking my time, I am more than happy with the weldments. I would divide each joint into 4 quadrants, welding a quadrant at a time. The underside quadrant was the tricky one, but after dozens and dozens of welds my hands and eyes even cranked these difficult welds out with good results. To ensure compliance to the 'full penetration over 360deg of the joint' rule, the cage was welded in the 'lowered' position for access to the roof bars. It was then lifted on 0.125" steel plate plinth boxes I welded to the factory sill stamping. It should be more than tough. And I feel really good about the fact that I handcrafted it myself -- even the local professional race driver and his shop were impressed with 'ze quality!

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