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  • Basket Repair Project.

    My customer and former associate Jason asked me to help him to repair a wire frame basket. I say former because we both retired from the same company in the last six months. Jason attempted to repair the by epoxy gluing it back together. Before too long the epoxy cracked at the joint. It was a case of man against hardware and hardware was winning. Jason wanted some help to win the battle. I guess you could say that it got personal. Below are two pictures of the basket with the epoxy.

    1. Basket with epoxy
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ID:	612456 2. Close up of epoxy joint
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    The first step was to remove the epoxy so that I could weld it.

    3. Chiseling the epoxy off
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    4. Epoxy removed
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    The next step was to sand and power wire brush off the paint. I found that the power wire brush worked better.

    5. Sanding off paint
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    Now I could finally weld it. I chose the oxyacetylene process, because I believe that the extra heat of this process tends to boil off impurities. I cleaned it a reasonable amount, but there was still paint near the wires of the basket that was difficult to remove.

    6. Welded joint
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    7. Several Welded joints
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    This is a mockup of my setup that I found worked best. I placed the backup bar about 1/16” from the 1/8” bar to prevent it from sucking too much heat from the bar. The wire of the basket was resting on the heat sink bar to help keep it cool. The challenge was heating up the 1/8” bar without vaporizing the wire.

    8. Backup bar and weight
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    The welding process burned up some of the existing paint, so I wire brushed it down to bare metal

    9. Basket all welded
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    To keep it simple I only painted the top of the basket, so I masked the rest.

    10. Masked for painting
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      Here is a close up and a view of the entire painted basket.

      11 Joints painted
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      12. Basket all done
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      -Don
      Last edited by Don52; 12-13-2020, 02:40 PM.
      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Lincoln 210 MP
      Clausing/Colchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        Kind of an odd thing to repair, Don. Is it sentimental wire basket or a one of a kind item?

        Comment


        • #5
          Originally posted by ryanjones2150 View Post
          Kind of an odd thing to repair, Don. Is it sentimental wire basket or a one of a kind item?
          I think that it perfectly met Jason’s requirements and it became a challenge or even an obsession for Jason to get it fixed. Jason obviously felt that it was worthwhile spending time applying the epoxy. I also believe that my welds will be a lot stronger than the original spot welds, which nicked the wires.
          Last edited by Don52; 12-14-2020, 08:54 AM.
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            I have no doubt. That epoxy is about the worst thing to try and get off to weld. Good choice in using O&A.

            Comment

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