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Cross Braces for I-Beam Gantry above Lathe

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  • Cross Braces for I-Beam Gantry above Lathe

    One friend gave me the top I-beam from an A-frame gantry crane, which I decided to mount on the ceiling above my Lathe in a direction parallel to the axis of rotation of the lathe. My plan is to mount a chain fall on the I-beam to lift heavy chucks and my turret and conventional tail stock for the lathe. Another friend gave me some 2-1/2" x 4" rectangular tubing left over from his jet ski lift project. I cut some 1" plate into 2-1/2" square pieces and turned a Ø1-5/8" boss x 9/16" deep on one side of the plate. My idea is to have the boss stick thru the 1/2" drywall by 1/16", with drywall resting on the square part of the plate. So after the drywall is installed and before the I-beam is mounted you will see four Ø1-5/8" bosses sticking out of the drywall by 1/16" on each end of the I-beam.

    The cross braces are constructed by:
    • Setting up the Lincoln SP-250 welder for short circuit MIG to weld the 3/16" plates to each end of a 2-1/2" x 4" rectangular tube
    • Temporarily installing the cross brace assembly between the joists using two nails on each side of the cross beam
    • Temporarily bolting the pucks to the I-beam and raise the I-beam assembly into position with the manual fork lift.
    • Setting up the Lincoln 210 MP welder for dual shield flux core to tack weld the pucks to the bottom of the tubing, using a horizontal and an overhead weld. I used dual shield flux core because I was concerned with cold lap if I used short circuit MIG to weld the 7/16" thick 2-1/2" square plate with the Ø1-5/8" round boss to the 3/16" thick rectangular tube.
    • Removing the cross brace and fully welding the pucks to the rectangular tube.
    • Re-installing the cross brace.

    The I-beam came with a plate welded to the bottom flange on each end. The plate was warped most likely from when the weld shrunk as it cooled, so I set it up on my arbor press to straighten it out.

    1. Isometric asm
    2. Exploded asm
    3. Exploded cross beam
    4. Drilling plates
    5. Turning pucks
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    sigpic
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    6. One puck turned
    7. Parts machined
    8. Straightening plate on I-beam-1
    9. Straightening plate on I-beam-2
    10. Straightening plate on I-beam-3

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    Attached Files
    sigpic
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      11. Short circuit welding of end plates
      12. End plate fillet weld
      13. Outside corner weld
      14 Adding one inch (because I measured wrong.)
      15. Dual shield welding of pucks

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      sigpic
      Miller Thunderbolt
      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Clausing/Coldchester 15" Lathe
      16" DuAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        16. Puck fillet weld
        17. Cross brace installed
        18. I-beam hung on brace from bottom
        19. I-beam hung from top
        20. bolted and nailed

        Click image for larger version

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        sigpic
        Miller Thunderbolt
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Clausing/Coldchester 15" Lathe
        16" DuAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          21. beam installed
          22. Chain fall
          23. Clausing-Colchester 15 inch Lathe
          24. Turret Tail Stock

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Name:	23. Clausing-Colchester 15 inch  Lathe.jpg
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Name:	24. Turret Tail Stock.jpg
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          sigpic
          Miller Thunderbolt
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Clausing/Coldchester 15" Lathe
          16" DuAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            Very nice!

            I saw where one guy had a lathe, mill and maybe one other machine. One end of the beam was hung on a fixed pivot point. The other end had rollers running on a curved pipe attached to the ceiling. It was about 1/4 circle, and allowed him swing heavy stuff and reach all the machines. Clever.
            --- RJL ----------------------------------------------

            Ordinarily I'm insane, but I have lucid moments when I'm merely stupid.
            -------------------------

            Comment


            • #7
              It sounds like a nice flexible design, with the curved track.
              My plan is to wheel a lift cart with a heavy chuck on it, to the right side of the lathe beyond the tail stock. I will then pick the chuck up with the chain fall and wheel it straight over the tailstock to the headstock of the lathe. The reason for the lift cart is so that I can slide or roll the chuck onto a shelf regardless of the height of the shelf. I will also use it to exchange the conventional tail stock with the turret tail stock. The chain fall is the low profile model and my ceiling is 9’4”, so I should have plenty of room for the chuck to pass over and clear the tail stock.

              -Don
              sigpic
              Miller Thunderbolt
              Smith Oxyacetylene Torch
              Miller Dynasty 200DX
              Lincoln SP-250 MIG Welder
              Lincoln LE 31 MP
              Clausing/Coldchester 15" Lathe
              16" DuAll Saw
              15" Drill Press
              7" x 9" Swivel Head Horizontal Band Saw
              20 Ton Arbor Press
              Bridgeport

              Comment


              • #8
                Have you made a chuck hook?

                --- RJL ----------------------------------------------

                Ordinarily I'm insane, but I have lucid moments when I'm merely stupid.
                -------------------------

                Comment


                • #9
                  No but that was exactly my plan.

                  -Don
                  sigpic
                  Miller Thunderbolt
                  Smith Oxyacetylene Torch
                  Miller Dynasty 200DX
                  Lincoln SP-250 MIG Welder
                  Lincoln LE 31 MP
                  Clausing/Coldchester 15" Lathe
                  16" DuAll Saw
                  15" Drill Press
                  7" x 9" Swivel Head Horizontal Band Saw
                  20 Ton Arbor Press
                  Bridgeport

                  Comment

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