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SKILL LEVEL: Advanced
TIME COMMITMENT: Weekend
Here's what you'll need to get started.
Tools used in building but not required:
WARNING: READ AND FOLLOW ALL LABELS AND THE OWNER'S MANUAL.
Using 1/8" 1x2 sq tubing for this part, cut 2 pieces 43" long with 45 degree cut on one end, a 28" piece with 45 degree cut on both ends, and one 26" piece. Be sure to debur your cut areas.
For bolting to the table, use six 3/8" fine thread bolts, and cut 1/8" wall 5/8 DOM tubing to 1 7/8" for crush tubes.
Using a carbide cutter or a bi-metal hole saw, drill three, 5/8" holes through the 1" side of the 43" long pieces at 4", 16" and 22" from the straight cut end.
TIG weld the crush tubes in. Set Multimatic® 220 AC/DC for 100 amps and use .045" size ER70S-2 filler. Note that you need to cut the tubes to 1 7/8" instead of 2" so you have 1/16" weld step on each side. This will give extra weld strength when grinding the welds flush to the sides.
Grind the mill scale off all the weld joints, square up the sides and tack weld inside and outside corners only. Don’t weld solid yet.
Clamp frame to the bottom of the ArcStationTM 30FX and double check that it’s parallel to the table. Now transfer punch the mounting holes for drilling and tapping.
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