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MP Welding Trailer

Page history last edited by Michael 5 years, 5 months ago

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Based on the U.S. military M103A3 utility trailer. It's a two-wheel trailer with a contractor's/military towing lunette, and a "landing wheel" for when it's not attached to a towing vehicle. The trailer weighs 775 kg without any of the tools or equipment loaded; it's 2.6 tons maximum total weight off-road. 4.3 meters long, 2.4 meters wide, air over hydraulic brakes (and a mechanical parking brake), and (for the Morrow Project) 11x20 tires.

32 Morrow Project vehicle batteries are fitted (total weight 80 kg) to operate the welder for 4 hours of continuous welding.

The trailer body has lots of doors on all sides, and a sort of "tunnel" through the middle for the welder itself; there's a small post with a chain hoist, and a work surface with a vice at the back.

tools
#	name
1	wrecking bar, 30"
1	chain hoist, hoist mass 10 kg, capacity 1/2 ton
2	cold hand chisel
1	ball peen hammer
1	6 lb sledgehammer
4	pliers, various types
1	rubber mallet
11	screwdrivers, various sizes and types
2	straight vice grip
1	wire brush
2	"C" clamps
2	set, welder's apron and helmet
2	pairs of industrial goggles (worn over personal spectacles)
2	welder's industrial goggles
1	electric floodlight
1	bench grinder
1	Milwaukee angle grinder, aka disc grinder, 11 cm diameter wheel, runs on 13 amp 120 volt AC power. cord 2.5 meter. Mass 3 kg
14	11 cm diameter metal grinding wheel, 0.25 kg each
12	padlocks, keyed alike
1	hand fire extinguisher
set	oxacetylene welding and cutting equipment. Metalworking or Mechanical Repair skill are needed to use this equipment well. 2 pairs of leather gloves 2 friction igniters 25 meter dual hose 6 cylinders of technical oxygen 4 cylinders of technical acetylene 1 cutting torch, 75 degree angle 1 welding torch
set	gas metal arc welding set, for up to 11mm aluminum or 5mm steel 2 pairs of leather gloves 11.5 kW Miller power supply, with wheels and tow handle (so it can be removed from the trailer), 3 meter power cord for 240 volt AC wall socket. The working current is 28 volts DC, 200 amps, at a 60% duty cycle. Weight 90 kg. 2 welding guns, with three nozzles each (inside corner, outside corner, and flat surface) 2 wire feed units (1.3 to 20 meters per minute) 1 spool (4000 meter) of 0.9mm ER5356 aluminum electrode wire, 7.3 kg 1 spool (3300 meter) of 1.2mm ER5356 aluminum electrode wire, 9.1 kg 2 spools (1800 meters each) of 1.6mm ER5356 aluminum electrode wire, 9.1 kg each 1 spool (1470 meters) of 1.6mm E70S-3 steel electrode wire, 23 kg each. For low-carbon steel or galvanized steel, with argon gas shielding. 2 spools (1270 meters each) of 1.6mm E70S-6 steel electrode wire, 20 kg each. For more alloyed -- or dirty/contaminated -- steel, with argon/carbon dioxide shielding gas. Also needed for armor steel, stainless steel, etc. 10 copper gun tips 10 meter gas hose 25 meter cooling water hose 10 meter power cable 15 meter work cable and clamp 6 cylinders of argon/carbon dioxide mix, 2265 liters each, each with valve and cap, 82cm tall. 18 cylinders of argon, 2265 liters each (used at 13 to 23 liters per minute), each with valve and cap, 82cm tall. A full tank has 3.75 kg of argon in it; an empty tank weighs 23 kg. 2 regulator/pressure gauge/flow meter for argon 2 regulator/pressure gauge/flow meter for argon/carbon dioxide mix 2 4 meter gas hose (regulator to welding machine) dual gas cylinder rack 2 chain for cylinder 4 wire brush various adjustment and repair tools, small parts and repair parts

GMAW electrode wire consumption
thickness	steel	aluminum
1.6 mm	0.03 kg/m	0.015 kg/m
3.2 mm	0.075 kg/m	0.03 kg/m
4.8 mm	0.15 kg/m	0.045 kg/m
6.4 mm	0.25 kg/m	0.075 kg/m
9.6 mm	0.5 kg/m	0.17 kg/m
11.1 mm	0.7 kg/m	0.24 kg/m
12.7 mm	0.9 kg/m	0.3 kg/m
15.9 mm	1.4 kg/m	0.4 kg/m
19.1 mm	1.6 kg/m	0.5 kg/m
22.2 mm	1.8 kg/m	0.6 kg/m
25.4 mm	2.2 kg/m	0.8 kg/m
A more skilled welder (over 40% Metalworking skill, or over 60% Mechanical Repair skill) will use half as much wire -- better technique, use of materials, preparation, etc.

manuals
#	name
1	US Navy Cutting and Welding Manual. Includes information on underwater cutting and welding.
1	manual for MIG welder
6	general manuals on welding
1	Cadillac-Gage manual for welding Cadaloy high-hardness armor steel
1	Welding Encyclopedia