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Welding of Boat Hoist Brackets

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  • Welding of Boat Hoist Brackets

    My friend and customer Mark owns a home on Lake Saint Claire here in Michigan. Recently the water level of the lake has been very high. The problem is that his boat hoist can’t lift the carriage that holds the boat high enough to get the carriage out of the waves. This causes the waves to beat the carriage to death. The boat hoist is constructed of four pylons. The two pylons on the right have winches on them and the two on the left have idler pullies on them. The winch has enough travel to lift the carriage of the boat hoist out of the waves but the idler side can’t keep up, because the cable will rub on the flame cut hole in the channel iron of the dock. The hole is already fairly large so it is undesirable to make it any larger, without compromising the integrity of the dock. Mark’s solution was to design a different bracket to hold the idler, which put the cable out far enough to entirely clear the channel iron. The first picture shows the entire dock.

    1. Boat dock-1
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    The next picture is a close up which shows the winches on the right and the idler pullies on the left.

    2 Boat dock-2
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    The third picture shows a close up of the original idler bracket. You can see that part of the problem is that the cable from the pulley to the cross brace of the carriage isn’t vertical. As the carriage is raised the angle of the cable causes it to get closer and eventually rub on the flame cut hole in the channel iron.

    3. Boat dock-3
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    My task is to weld on the new brackets on the idler side of the boat hoist as shown below. Unfortunately, the dock on the idler side is only 18 inches wide.

    4. Hoist site view
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    The next three pictures show the bracket that needs to be welded to the pylon. The required weld is shown in purple. The cable is shown in red and as you can see it is well away from the channel and vertical.

    5. Bottom view of bracket
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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
    6. weld view1
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    7. weld view 2
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    The pylons were driven 30 years ago and the pipes weren’t new when they were driven. The pylon closest to the shore was in very good shape.

    8. Land side pylon
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    The next two pictures show that the offshore pylon was a little pitted from rust.

    9. Offshore pylon 1
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    10. Offshore pylon 2
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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
      This is a picture of me welding the offshore bracket to the pylon.

      11. Welding bracket
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      Before I welded the bracket, I tack welded the four corners to keep it from moving during welding.

      12.Tack-1

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      13. Tack-2
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      14. Tack 3
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      The first pass was done with the following:

      Vertical plate: ½” thick
      Tube: Ø8-1/2 5/16” thick

      Rod: 3/32” 6011
      Current: 80 amps
      Polarity: DCEP
      Dig: 50%
      Motion: Whip and pause with slight wiggle on the bottom forming an inverted Tee.

      15. First pass
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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


      • #4
        The second pass was done with the following:

        Rod: 1/8” 7018
        Current: 105 amps
        Polarity: DCEP
        Dig: 30%
        Motion: Inverted Vee

        16. Second pass
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        I beveled the ¼” top plate at a 30° angle. It had a 3/32” root gap.

        The first pass was done with the following.

        Rod: 3/32” 6011
        Current: 80 amps
        Polarity: DCEP
        Dig: 50%
        Motion: Whip and pause

        The second pass was done with the following:

        Rod: 5/32” 7018
        Current: 140 amps
        Polarity: DCEP
        Dig: 30%
        Motion: Cursive U’s

        17. Top Weld
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        The left side weld parameters were similar to the right-side weld.

        18. left side pylon-1
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        19. Left side pylon-2

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        I also patched the original hole in the channel iron.

        20. Patch
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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


        • #5
          Here is a picture of the offshore pylon with the new bracket welded in place.

          21. Offshore pylon done
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          Here is a picture of the Land side pylon with the new bracket welded in place.

          22. Land side pylon done
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          Here is a close up of the two pylons with the new idler brackets welded in place.

          23. two pylons done
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          Here is the boat hoist all done.

          24. Boat hoist done
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          -Don
          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
            Looks great
            I do grind the old steel. It makes spatter stick but makes the edges wet out. Not important here, the appearance is good and it's super strong.

            Comment


            • #7
              I’d say this was a very well planned and executed modification. And as always, Don, well documented and explained.

              Nice view from the dock too!

              Comment


              • #8
                Nice Work.......For outside in the weather where shielding flux or gas can be a problem especially on rusted parts. Love the Pic's

                Comment


                • #9
                  Originally posted by Sberry View Post
                  Looks great
                  I do grind the old steel. It makes spatter stick but makes the edges wet out. Not important here, the appearance is good and it's super strong.
                  Thanks.

                  Originally posted by ryanjones2150 View Post
                  I’d say this was a very well planned and executed modification. And as always, Don, well documented and explained.

                  Nice view from the dock too!
                  It was a very peaceful place.

                  Originally posted by tarry99 View Post
                  Nice Work.......For outside in the weather where shielding flux or gas can be a problem especially on rusted parts. Love the Pic's
                  It has been raining almost every day here in Michigan, so it took us awhile to find a day that had no rain and light wind. We were fortunate to find such a day..

                  -Don
                  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


                  • #10
                    Mark primed the welded area and hooked up the cables. It worked as expected. Here are a few pictures.
                    Click image for larger version

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                    Click image for larger version

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                    Mark said that he was going to remove the pulleys that provide side tension to the cables, which are shown below, because they no longer serve any purpose.
                    Click image for larger version

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                    Mark also said that the hoist now lifts the boat high enough to get the carriage that holds the boat out of the waves. Yippee.

                    -Don
                    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


                    • #11
                      Mission accomplished.

                      Comment


                      • #12
                        I understand Dons position. This is in a visable spot, the clean work shows and speaks for itself. If I was doing this as a,,,,,,,,,,,,,,,,,,,,, contractor,,,,, for lack of better wording would have whacked the post with a grinder a little and not beveled or root fit any of this and most likely a pass or a simple root stinger with the 6010 and a 3.32 wash/cover or a single pass 1/8 7018.
                        I do understand none of that makes any difference on this job. Most jobs like this a few minutes are irrelevent, I do the same, fuss over some for good customers when it makes a difference.

                        Comment


                        • #13
                          A lot of people worry a lot about liability and such but doing a neat job removes a lot of that. It would be tough to try to find fault with that. I avoid the inspectors like a plauge but they aint out looking to find who dun this mess. The electric inspector thinks I am an electrician and I dont really tell him any different.

                          Comment


                          • #14
                            I also do the same cleaning and "dressing" with the grinder. Makes for great paint finish when the spatter, humps and sharp edges dressed and leveled off so the paint doesnt run off. That kind of cleaning makes for long lasting paint. I been doing it long enough its about a reflexs and zippy fast and sometimes not even notice or eye catching that its been done. No holes and pockets for water to sit.

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