My first project - Gearbox trolley.

  1. Alan Easton

    Alan Easton New Member

    Messages:
    4
    Location:
    Warrington, Cheshire, England
    Hi all,

    I just joined up but have been reading a bit on here about MIG welding, gas, welders etc.

    I'm not a welder but I guess a hobbyist. Anyway, after much deliberation and some financial quandary, I ended up buying a Röhr MIG-200MI from Amazon, I then went through the ringer with disposable bottles, gave up and bought a 10l 200bar Tri-mix bottle and rigged it all up.

    I had been doing a bit of stitch welding and rust repair to my race car and the progress caught the eye of a local race car company who asked if I wanted some steel to practice on... I couldn't say no!

    So as with everything, the catch was that if my welds were good, they'd like me to put together a gearbox trolley for the quick removal and replacement of the gearboxes on one of the LMP racecars they are currently building.

    How could I say no!?

    So here it is, the only spare stock steel they had was pretty manky, covered in millscale and light surface rust. The flap wheel and grinder made it look a bit better but still tricky. I'll just post a few pictures up now and await the roasting lol.

    As I say, never done anything like this before but I'm proud of my achievements. The trolley isn't complete year. A 2mm thick sheet is needed on the top and some securing screws will be installed to ensure the gearbox doesn't move around once on the trolley and removed from the car. The trolley was put on a level setup platform and I managed to achieve a 0.1mm wobble and the top was 0.07° out of line with the base. To rectify this, we put washers in between the trolley and one caster, this bright it perfectly level with the gearbox base.

    I'm quite pleased with it and can't wait to get back to finish the top and then get it powder coated.

    Any tips, tricks or advice always welcome.

    As for setup... The Röhr held up to the job well. The metal was 2.5mm box so I set wire speed to 4, Voltage to 7 and the gas was set to 60psi and 15L/min. It seemed to do well. I'll have to measure the wire speed etc won't I as I just realised the setting won't relate to anything that could be referenced to another welder lol.
     
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  2. dyno-tron

    dyno-tron Member

    Messages:
    124
    Location:
    Near Chester, UK
    Great job! One suggestion, as the trolly is quite narrow and on pivoting castors, it will be at risk of tipping over with a gearbox on top if it is being moved sideways.
    You may want to consider making some outriggers to fix the castors to. I did similar with an upright go kart stand, made it much more stable.
     
  3. colnerov

    colnerov Member

    Messages:
    3,360
    Location:
    Nr Gatwick UK
    Hi, I agree, or fixed wheels one end which will reduce the likely-hood but still be reasonably manoeuvrable.

    Colin
     
    Alan Easton and dyno-tron like this.
  4. Alan Easton

    Alan Easton New Member

    Messages:
    4
    Location:
    Warrington, Cheshire, England
    Good idea!! I'll have a word with them and see if they have any fixed castors... If not, I guess I could weld the two back ones into place to stop them spinning.
     
  5. Alan Easton

    Alan Easton New Member

    Messages:
    4
    Location:
    Warrington, Cheshire, England
    Yeah, as above, I'll see what they say and maybe replace for fixed castors or weld two of those in the dead ahead position lol.
     
  6. dyno-tron

    dyno-tron Member

    Messages:
    124
    Location:
    Near Chester, UK
    Found a couple of pics of the ones I did. I just chopped up some box section that was spare. IMG_20200523_160245.jpg IMG_20200523_160221.jpg
     
    Alan Easton, slim_boy_fat and Ruffian like this.
  7. badabec Forum Supporter

    Messages:
    124
    Location:
    Essex UK
    Couldn't agree more. I made trolley for my genny with castors from Tesco (cost £1). When you go sideways, the thing falls over for looking at. OK with a small genny, not much fun with a gearbox.
     
    Alan Easton and dyno-tron like this.
  8. Alan Easton

    Alan Easton New Member

    Messages:
    4
    Location:
    Warrington, Cheshire, England
    Back up to finish the job tomorrow so I'll have a chat and see what they say. That's a good idea though.
     
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