I know you are a better welder than I am, so maybe you can give me some advice here.
First up, I have an Esab 260 Multimaster (wire feed 70 R3 wire, and DC stick up to 300 amps, plus torches).
Because of serious risk of somebody getting hurt or maimed if a load falls when a fork breaks, I will not be welding the broken ones. I bought nearly new ones 2" thick X 6" wide at the top of the fork X 48". They look to be in excellent shape, and still have the manufacturer's stickers on them. But the fork carrier frame I have needs a loop at the top of the fork (these have the very stout hook that rides on a vertical flat, notched fork carrier. The rod holding the forks on my carrier is 1.75" diam, and never bent. The loops on the old forks are 1/2" wall thickness hollow tubing welded to the top edge of the fork.
So my plan is to get some round tubing with 1/2" wall thickness with a 2" diam bore, and weld them to the tops of each fork, with no need to eliminate the stout welded hook that is just below the top edge. The oversize bore is to allow some ease of fork movement on its support rod and make the possible weld distortion and shrinkage of the welded tube a non critical issue. I have not bought this steel yet.
The welding plan: 1) Clean all oil residue from the top area of the fork. 2) preheat the weld area with a big propane torch. 3) Lay a root weld with 6011 DC. 4) Layer up with 7018 DC.
As the shielded wire (.035) is faster to use, I would prefer to use that, but am concerned with not enough penetration. What's your thoughts about wire VS rod, and any recommendations about welding proceedure? I hope to do this within the next week.
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