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View Full Version : Z Bars Construction/ Destruction



camoback
08-24-2009, 1:26 PM
First go around on making some bars, actually really making anything. Been on deployment and tried to pick up some welding and this is the end product of that time.

first step is to find some 1 inch tubing from a iraq junk lot and hope it wasn't a shitter pipe. for this set i chopped it into (5) 10" pieces

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200065.jpg

next with (1) 10" piece cut both ends off at 45 degrees and (2) pieces cut ONE end off at 45 degrees.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200069.jpg

then file or grind edges to get it clean for welding and better fit. i didnt spent too much time on fit due to my lack of skill in welding and knowing i was going to bugger it up to some extent anyways. in retrospect prep is everything and i probably wouldnt have blown through as much if the fit was tighter. plus stick welding and my lack of skill didnt help.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200067.jpg

next square up the 3 pieces and tack them up. a jig would help or a third hand but whatever.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200070.jpg

camoback
08-24-2009, 1:27 PM
now the tricky part, at least for me. to determine the angle of the down portion of the bars and the actual handle to cut, you can use some fancy ruler or some brainy formula which i attempted but the dummy side of me came to the conclusion of drawing a picture. i drew out the bars and the angle of the handle portions and drew a straight line at the connecting corners. then i held the bars over the drawing and matched up the lines on the bars and Bam! got my angle.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200073.jpg

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200074.jpg

after i cut the bars and put it up in a vise and using my eyeball meter and the S.W.A.G. formula (Scientific Wild Ass Guess) i tack welded the handle bar portion and played with it till i got the shape i wanted. one thing to take into consideration which i didnt is when traceing out your angle for the handle portion, take into consideration of the angle of the pull you want the bars to come back at. when i did mine i did it flat to the table so when i matched it up i had some good gaps in between the bars which i just filled in with welds. not the best method but it worked. just caused a bit more sweat.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200078.jpg

after that finish up the welding, and depending on what your skill is, you can finish up fairly quick or spend all day chasing spots you burned through like i did. for every corner i probably had to go over ten times form burning thru. i know i suck.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200080.jpg

camoback
08-24-2009, 1:28 PM
make sure you alternate welding corners to let it cool and constantly recheck the angles to make sure it doesnt move on you from the welds. if it does a hammer does come in handy. one thing that happened with mine is that since i burned thru couple times on the inside, i built it up nice and thick and it caused the bars to be pulled to the inside a little which gave it a nice little stance. after, use a grinder and a flapper wheel to clean it up and make it look presentable. how did i ever get thru life without a flapper wheel is beyond me.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200085.jpg

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8200087.jpg

who said you cant polish up a turd !!!!!!

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8220088.jpg

I got froggy the next day and made these. yes i know they suck but its a start.

http://i619.photobucket.com/albums/tt273/camoback123/Handlebars/P8220089.jpg

not too much longer and ill be back riding and enjoying the wind. hope this helps someone.

rusjack
08-24-2009, 1:32 PM
hahaha wicked. i love that you did those with a stick

billybiltit
08-24-2009, 1:39 PM
100% percent penetration is insured when filling gaps and holes,hehe.
just shows ta go ya that you don't have to have a tig to build some cool shit!
way to get it done with the stick,congrats!!!!!

leon holmes

STANDARD
08-24-2009, 5:07 PM
another thing you might wanna do is clean alittle farther back where the weld is going to be , and then on the joints where the mate up make sure they mate PERFECT, and file or grind the edges to a 45 degree so that when you weld it not only gets the 2 joints fused better ,but it will put more material down, for EXTRA strength.

just my .02 .... but what the fuck do i know?

LilGeneral
08-24-2009, 6:44 PM
Don't take this wrong but...
1 You should clean your steal before welding,
2 You need to turn your heat down on that thin of tubing or get thinker tuding and "V" the edges.
3 Smaller grinder to get better control you seem to have a lot of "back cut"
4 Are you using solid of flux core wire ?

practice makes perfect

camoback
08-25-2009, 3:27 AM
Don't take this wrong but...
1 You should clean your steal before welding,
2 You need to turn your heat down on that thin of tubing or get thinker tuding and "V" the edges.
3 Smaller grinder to get better control you seem to have a lot of "back cut"
4 Are you using solid of flux core wire ?

practice makes perfect

thanks for the replies so far.
1. i agree about the cleaning but only had a limited time in the shop. plus i said screw it.
2. tried on adjusting the heat but kept sticking or cold rolling. plus i suck at it
3. only used what was available
4. it was stick/ arc welded

true on the practice. have to start somewhere.

redlined24
08-25-2009, 3:56 AM
hell ya man, i like em,

mcdowell72
08-25-2009, 7:28 AM
personally i think those Z bars turned out pretty bad ass, especially considering what you had to work with. plus i'd bet you're the only guy on here who can say they've made their own bars out of scrap steel they found in iraq.

sumo
08-25-2009, 10:55 AM
as for cleaning before arc welding - quick wire brush to get rid of anything loose generally suffices

i arc pretty much everything. once you get the way of it you can do pretty delicate things, including thin stuff like tanks but that is hard and time consuming

its excellent for tabs and general fab - great penetration, not too picky on cleanliness, cheap to run, weld outside or in, no gas, quick to setup, grab weld something and put away etc... i believe it is one of the most versatile welding methods thats fairly easy to grasp the basics of then away you go making strong joints not like a crappy mig that struggles with anything over a penny thick

stick at it and weld anything you can get your hands on.

also id be a bit carefull with the grinder too - looks like you are taking off lots of metal other than the weld. with practice you can row pennies up with an arc setup and not have to grind if you like that look of a tidy weld

willythepirate
08-25-2009, 1:15 PM
I love it!! TAx dollars hard at work!!


(I'm not talking shit I did the same kinda dumb shit in Afghanistan)

cafcustoms
08-26-2009, 12:40 PM
as for cleaning before arc welding - quick wire brush to get rid of anything loose generally suffices

i arc pretty much everything. once you get the way of it you can do pretty delicate things, including thin stuff like tanks but that is hard and time consuming

its excellent for tabs and general fab - great penetration, not too picky on cleanliness, cheap to run, weld outside or in, no gas, quick to setup, grab weld something and put away etc... i believe it is one of the most versatile welding methods thats fairly easy to grasp the basics of then away you go making strong joints not like a crappy mig that struggles with anything over a penny thick

stick at it and weld anything you can get your hands on.

also id be a bit carefull with the grinder too - looks like you are taking off lots of metal other than the weld. with practice you can row pennies up with an arc setup and not have to grind if you like that look of a tidy weld

Hey Sumo, I agree. Arc is all I've ever used - Only recently on bikes but had plenty of experience on plant and general fabbing.

Did all of my hardtail, bracketry, bars and sissy with my 20 yr old 180 amp diy arc.

http://i133.photobucket.com/albums/q60/bigusnickus/P1020852.jpg

billybiltit
08-27-2009, 2:19 PM
props to sumo for the positive take on arc welding.so many folks just want to tell ya to just get a cheap mig.arc can be done as well as any with some practice.
camoback,thanks for doin what you do over there.even if it is just building bars,hehe.

leon holmes

SportsterBob
08-28-2009, 1:29 AM
I made the bars by my self too.
wasn't easy, but I love it ;)

http://c4.ac-images.myspacecdn.com/images02/3/l_caf7f456ad72432b83b8ae71d117bb5b.jpg

http://c1.ac-images.myspacecdn.com/images02/4/l_a894af79872b409fae816df608f9d04c.jpg

camoback
08-28-2009, 12:06 PM
good gouge and things to think about. in retrospect i should of went with a thinner rod. i used 6010. also i could of went 7018 which would of came out cleaner (i might of got that backwards). a dremel would of been cool too but enough excuses. will get better through time. thanks for the support by the way, just something to throw out and it probably applies to 95% of the guys here currently is that really alot of nothing is going on over here. the guys in afganistan are the ones who need the support and dodging rounds.give them the accolades.

eliwolf6
08-28-2009, 7:24 PM
nice work man,, i need to pick up a welder of some sort.. we been usin our mechanics truck mounted miller. it's just to big, cant hardly turn it down low enough.. blow through everything... anybody used that red arc welder from home depot?

jason43
08-28-2009, 10:38 PM
Looking good, I'd be really careful about running home made bars unless you know 1000% that the welds are good, like you didn't burn up the metal and create weak points. There is pretty much no where that you would want failure to happen less than your handlebars. Great for practice though. Take care and be safe over there.