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Thread: Forced Induction Section Fabrication Thread

  1. #1601
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    Quote Originally Posted by somebody5788 View Post
    80 fpm is too fast? It has 3 speeds 80 to 200 fpm
    Oh shoot i shoulda clicked the link. The vertical saw is too fast. That combo horizontal/vertical is the right speed.


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  2. #1602
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    Got my Mig supplies today. The guy at my local airgas said for mig welding stainless i should use 100% argon gas and a .030 ER308/308L wire. So thats what i got. Sound right?

  3. #1603
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    Maybe next round get Tri-mix for mig welding stainless.

    100% argon is for tig the majority of the time.
    1996 332IS
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  4. #1604
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    Quote Originally Posted by Butters Stoch View Post
    Maybe next round get Tri-mix for mig welding stainless.

    100% argon is for tig the majority of the time.
    Good to know. Next round will be cheaper. $20 for a refill or $120 for a tank. Dann son. I still ended up buying two tanks. One for stainless and one for mild.

  5. #1605
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    I have mig welded stainless and mild with 100% argon and it works like shit in both.


    86 325es, 2.8L m50, S476sxe, ProEFI 128 ecu, e85, solid rear axle, TH400 trans, 28x10.5w slicks, zip ties, popsicle sticks, tape
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  6. #1606
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    Well I made my first welds today. Probably should have started with something other than the reinforcement plates for the rear subframe. But it's been done. I just stitched it, so I figure I can go back over and redo it if need be. Also I think I should have spent twice as long cleaning. Take a look at these beads and tell me how I can improve. Thanks.

    0323172054.jpg

    0323172054a.jpg

    0323172054b.jpg

  7. #1607
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    It would help alot if you had a Co2 argon mix. With pure argon it doesn't penetrate.


    86 325es, 2.8L m50, S476sxe, ProEFI 128 ecu, e85, solid rear axle, TH400 trans, 28x10.5w slicks, zip ties, popsicle sticks, tape
    best time 9.06 @ 151.8 mph, best 60 foot 1.30

  8. #1608
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    Quote Originally Posted by someguy2800 View Post
    It would help alot if you had a Co2 argon mix. With pure argon it doesn't penetrate.
    Those welds were made with a 75%/25% Co2 argon mix. Wire speed was about 35/100, Voltage was 4/5, gas feed was at about 20-25 psi. Wire used was er70s-6 .030 inch
    Last edited by XnWarden; 03-23-2017 at 10:08 PM.

  9. #1609
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    You really need to clean down to bare steel before welding. Here is a pic of the prep I did before welding those reinforcements in. It makes all the difference.
    1996 332IS
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    CES/Steed TS Precision 6466, spraying a "$π!℅" load of meth.
    Technique Tuning 80# tune.
    1/4 mile 10.84 @ 136.72
    Your 1 and only stop for all your BMW performance needs
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  10. #1610
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    Quote Originally Posted by Butters Stoch View Post
    You really need to clean down to bare steel before welding. Here is a pic of the prep I did before welding those reinforcements in. It makes all the difference.
    Yeah i kinda figured my prep work was shitty. Do you think i should redo it? Or will mine hold?

  11. #1611
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    Quote Originally Posted by XnWarden View Post

    Yeah i kinda figured my prep work was shitty. Do you think i should redo it? Or will mine hold?
    It will hold. Or clean better, and stitch another section. Turn the wire feed down and heat up.
    1996 332IS
    Built 3.2
    CES/Steed TS Precision 6466, spraying a "$π!℅" load of meth.
    Technique Tuning 80# tune.
    1/4 mile 10.84 @ 136.72
    Your 1 and only stop for all your BMW performance needs
    WWW.CESMOTORSPORT.COM

  12. #1612
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    Quote Originally Posted by Butters Stoch View Post
    It will hold. Or clean better, and stitch another section. Turn the wire feed down and heat up.
    Thanks for the input. Ill touch it up a lil. Welding overhead from your back sucks so much compared to sitting or standing and welding down. Any tips for getting a good torch angle?

  13. #1613
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    the right ratio of amperage and wire speed is really critical with mig. Play with it on a piece of scrap to dial it in first. I agree that more amperage is needed.


    86 325es, 2.8L m50, S476sxe, ProEFI 128 ecu, e85, solid rear axle, TH400 trans, 28x10.5w slicks, zip ties, popsicle sticks, tape
    best time 9.06 @ 151.8 mph, best 60 foot 1.30

  14. #1614
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    One more point to add..

    Lots of the strength from a sheet metal reinforcement like this comes from the rosette weld. You missed every single one of them on every plate.. You should really fill those in.

  15. #1615
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    Rosette weld: A type of circular weld created by making a hole in one section of a tube or blind channel and joining it to a second piece inserted inside. Also known as a rosette weld.

    The holes in the plates get filled in with weld, connecting the plates to the body.
    Last edited by chikinhed; 03-24-2017 at 10:05 PM.
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  16. #1616
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    Quote Originally Posted by chikinhed View Post
    Rosette weld: A type of circular weld created by making a hole in one section of a tube or blind channel and joining it to a second piece inserted inside. Also known as a rosette weld.

    The holes in the plates get filled in with weld, connecting the plates to the body.
    Gotcha, thanks for clarifying. Ill weld in those holes.

  17. #1617
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    Quote Originally Posted by Kevin325i View Post
    One more point to add..

    Lots of the strength from a sheet metal reinforcement like this comes from the rosette weld. You missed every single one of them on every plate.. You should really fill those in.
    Quote Originally Posted by chikinhed View Post
    Rosette weld: A type of circular weld created by making a hole in one section of a tube or blind channel and joining it to a second piece inserted inside. Also known as a rosette weld.

    The holes in the plates get filled in with weld, connecting the plates to the body.
    Visual aids, and going one step further, to reach the heavier gauge panel above the thin sheetmetal (E-46 M3 Touring)l:





    All paint ground off and hit with a coat of Copperweld (which works great, but despite efforts to clean tip/tube, clogs up to be useless the next time you try to use it; I'll try another can in a few years, to see if they've improved it...)



    I seal-weld around the entire plate, as well as the plug-weld, to prevent any moisture from getting between the panels.



    Surface ground flat and primed



    Seams sealed.



    Prep for and application of rubberized textured undercoating.





    Match factory E-coat color with PPG paint.



    You're welcome to view the whole album to see an M3 trunkfloor assembly being fitted to this E-46 Touring (so the S-54 M3's exhaust could be fitted.








  18. #1618
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    Quote Originally Posted by Randy Forbes View Post
    You're welcome to view the whole album to see an M3 trunkfloor assembly being fitted to this E-46 Touring (so the S-54 M3's exhaust could be fitted.
    That there is baller to the n'th degree!!

  19. #1619
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    So, this Harbor Freight Band Saw is AMAZING!!!!!! Finished the hot side piping up, the cuts were so perfect that I mostly just fusion welded everything with only a little filler in a couple spots.

    So I do realize my welds are a little too gray, at this point that's fine as I really didn't want to have a bright polished pipe under the hood. I will probably get it powder coated with some sort of textured finish. That being said this is technically my first real project TIG welding and the most SS experience I've had before was a few practice lines on a plate. I think I did ok for being so new to it.

    IMG_20170327_175649305_HDR.jpg IMG_20170327_192859749.jpg IMG_20170327_192911520.jpg
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  20. #1620
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    some master welders in this thread
    98 Estoril ///M3 4/6
    S54 swap CSL

  21. #1621
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    Quote Originally Posted by somebody5788 View Post
    So, this Harbor Freight Band Saw is AMAZING!!!!!! Finished the hot side piping up, the cuts were so perfect that I mostly just fusion welded everything with only a little filler in a couple spots.

    So I do realize my welds are a little too gray, at this point that's fine as I really didn't want to have a bright polished pipe under the hood. I will probably get it powder coated with some sort of textured finish. That being said this is technically my first real project TIG welding and the most SS experience I've had before was a few practice lines on a plate. I think I did ok for being so new to it.

    <img src="https://www.bimmerforums.com/forum/attachment.php?attachmentid=596427"/> <img src="https://www.bimmerforums.com/forum/attachment.php?attachmentid=596428"/> <img src="https://www.bimmerforums.com/forum/attachment.php?attachmentid=596429"/>
    The gray will be either too much heat or not enough gas coverage.
    Stainless steel is a "get in, get out" situation.
    Pipe like that only needs 50-60amps to fusion weld, 10-15cfm argon . if you pulse with the pedal, or set the machine to pulse or will keep the heat down a little. Or take your time and skip around from tack to tack.

    Good job !
    1996 332IS
    Built 3.2
    CES/Steed TS Precision 6466, spraying a "$π!℅" load of meth.
    Technique Tuning 80# tune.
    1/4 mile 10.84 @ 136.72
    Your 1 and only stop for all your BMW performance needs
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  22. #1622
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    Quote Originally Posted by somebody5788 View Post
    So, this Harbor Freight Band Saw is AMAZING!!!!!! Finished the hot side piping up, the cuts were so perfect that I mostly just fusion welded everything with only a little filler in a couple spots.
    Link to said saw?

  23. #1623
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    Quote Originally Posted by boostd4 View Post
    Link to said saw?
    http://www.harborfreight.com/horizon...saw-93762.html

    First thing is clean out the gearbox and replace the oil. Then just properly adjust the blade using a square against the table. Once it's setup right it's good to go. I've been using the blade it came with on 309SS without any issues so far. Will upgrade to a starrett blade later.
    1997 328is - Megasquirt PNP, Holset HX35, Deka 80lb injectors, SPA T3, Precision PW39 WG, Synapse Synchronic BOV, DKM Organic Twin Disc Clutch, Innovate LC-2 W/B, Mishimoto Intercooler, Mishimoto Catch Can, Mishimoto Rad, Devils Own Meth, Porsche 911 calipers with E46 M3 rotors, Corsa Exhaust

  24. #1624
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    For a regular guy, who isn't an instagram showoff welder (yet ), those welds look great!

  25. #1625
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    Pulsing will help but I wouldn't use it to fix this problem. Pulsing should be used to improve good technique not cover bad. With stainless it's critical not to linger. Use more heat than you think you need and get moving, fast. Also make sure you have good gas coverage. If your machine allows it, try turning up the pre-flow. Using a gas lens helps a lot too, I like the Furick FUPA or sometimes even the Weldtec Megaflo. Beware that these lenses require a lot more flow to work properly (25cfh for the Furick, 30+ for the Megaflo).

    It also probably means you're not backpurging. Probably not a huge deal for a charge pipe but if you're going to do stainless work on anything load bearing, backpurging is critical with stainless welding or you compromise it significantly. If you have black "sugar" on the back of the weld, that part of the weld will lose the corrosion resistance and will corrode and crack in time.

    One tip I recently picked up for welding stainless structures where back purging is not practical, like boxed structures (I'm making a tubular structure), this is the saviour. On the youtubes they say you have to use methanol but it's not true, that's only if you have to meet mil spec. Otherwise it works just as well with Isopropyl.

    http://www.solarflux.com/Pages/Productinfo.html

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