How to weld canopies on the gate from corrugated board. Learning to weld hinges on the gate - step by step instructions. Mounting hinges to round poles

The operation of welding hinges is an obligatory part of the installation of metal entrance doors, gates and gates. In order to weld fittings, the master will definitely need an electrode welding machine, a welding mask, and overalls.

It is necessary to prepare bearing metal loops (they should be the stronger, the heavier the future design will be). A grinder, grease, lithol or other oily liquid is also useful.

The order of work here will look like this (for convenience, imagine that the hinges must be welded onto ordinary metal gates).

First, thick metal plates are welded to the hinges - they are called plats or ears. It is done like this:

• two plates are laid horizontally so that there is a gap of about 2-3 millimeters between them;
• a loop is placed in the gap;
• these same plates are welded to the loop with a continuous seam - one to the upper part of the loop, the second to the bottom.

The presence of ears greatly facilitate further work and increase the life of the gate. They do not allow the canvas to "break" even with the heavy mass of the entire structure.

markup

In the next step, you need to raise the door leaves to a vertical position and install them “idle” where they should be located.

Do not forget that the sashes should open outward. If they open only inward, then in winter with heavy snowfall this will turn into serious problems.

Then you should mark the places for the future installation of the hinges on the gate - they should be located at a distance of about 20 centimeters from the lower or upper border of the canvas.

Sometimes, if the structure weighs too much (more than 200 kilograms), another additional fitting is placed in the upper part of the support.

All hinges must be installed strictly vertically, even a tiny misalignment during welding will lead to difficult closing or opening, and therefore to the rapid destruction of the support bearings. The evenness of their position can be checked with a plumb or laser level.

Welding

Now you need to use the welding machine: first, the fittings are welded to the door leaf, and only then to the support pillars. At the same time, it is necessary to constantly monitor the quality of the resulting seams.

When all welding work comes to an end, it is advisable to process new seams with a grinder.

You can weld the hinges on the gate, the garage door and on the metal door according to the same scheme as described above.

However, it should be noted that the master usually has the opportunity to weld the fittings on the door at the moment when it is in a horizontal position on a flat area, which greatly facilitates the process.

This does not work out with gates: support pillars, as a rule, are installed much earlier than they proceed directly to the installation of canvases.

Which hinges to choose

When choosing loops, be sure to focus on the parameters of the object on which they are going to be welded. Garage hinges, by definition, should be larger and stronger than hinges for a modest gate or door.

Usually for gates and metal doors, hinges with a ball-bearing are used. Moreover, such hinges and hinges in them can be of different shapes:

• cylindrical;
• square;
• hexagonal;
• drop-shaped.

Most often, cylindrical models have been used recently, square and hexagonal options are much less common in hardware stores.

And about the last drop-shaped loops (canopies) in the list, special mention should be made. Their use allows you to slightly simplify the installation process. Ears do not need to be attached to them first - this is the main advantage of the teardrop shape.

Without any preparation, such loops can be welded to the support post. Moreover, only the top of the lower part of the canopy should be in contact with the post, and the top of the top should be attached to the door leaf.

Teardrop-shaped products must be welded carefully - after welding, they should still rotate easily and freely. And only if this is true, you can proceed to further work.

Other features of welding fittings

There are a few more nuances that you need to know about for those who are going to weld the hinges. First of all, you should always weld the lower part of the fitting.

The hinges must be welded to the round posts with an offset of 5 millimeters towards the opening. This offset allows the gate to open as wide as possible without any obstacles. At the same time, for rectangular or triangular supports, no such manipulations are necessary.

Welds must be even, strong and deep. The presence of gaps in such seams is unacceptable.

When welding vertically, it is very important to choose the correct lead speed. Experts advise home craftsmen to resort in this case to circular smooth movements that will, as it were, lift the current metal up.

Welding work requires the performer to strictly observe safety precautions. It is necessary to start welding the fittings only when protective equipment is put on and all flammable objects nearby are removed.

To weld the gate with your own hands, you will need the initial skills of an electric welder, which will allow you to put a short seam and assemble the structure. The most common way is to weld a wicket from shaped pipes.

They assemble the simplest frame and sew it up with any material. Regardless of the beauty of the design, it has a number of advantages compared to gates made of other materials.

The gate can be made from a corner, but the profile has a number of advantages. The design of it has a large margin of safety. For such a gate, this quality is especially important. It is not only static loads, but also dynamic ones with multiple daily openings.

The profile pipe is inexpensive, in comparison with other types of rolled metal products with the same technical characteristics. With good processing after welding, the structure will serve for a long time.

With the help of squares, you can make a gate of any configuration. It can be deaf, sewn up with multi-colored durable corrugated board, flat slate, sheet metal "cards". The gate is decorated with forging elements or simply sheathed with a metal mesh and profile sections.

The design itself is quite simple to manufacture by electric welding.

Two standing parts must be welded with 3 crossbars and sewn up with corrugated board. The only difficulty is welding and installing loops.

If you manage to weld the gate, then you will become subject to other frame structures for the house.

It is possible to manufacture a gate without welding. Details are fixed on brackets and bolts. But welding is a more reliable and durable option.

Dimensions and shape

You can weld the gate in the form of an arch, an ellipse and any other shape. The most popular shape is a rectangular one with several ribs to hold the pillars together and stiffen them. Installation together with columns is possible, but most often the gate is hung on loops of already standing columns.

Common dimensions of parts for the simplest design: height 2100 mm, various widths, depending on the installed poles.

Old households were equipped with rather narrow and uncomfortable gates, so you may have to make changes to the fence by moving the posts and widening the opening. As a rule, the entrance is made 1000 mm wide.

materials

The pillars are made from a profile pipe with a shelf size of 80 or 100 mm. Taking into account its lowering into the ground by 800 mm, the length of the pillars should be 3 m. Plugs are welded to the upper ends to prevent water from entering.

For greater rigidity and fixing of the rack, it is possible to weld small pieces of reinforcement or other rolled steel, 1 m long, on the segment that goes into the ground.

For stand-ups, they take a profile 40/40 or 40/60, cut off two parts with a length of 2100 mm with a grinder. Cut pipe edges at a 450 angle for a larger weld area and secure fastening.

The upper and lower lintels are prepared from the main profile, with a gate width of 1000 mm. parts are cut with a size of 980 mm. This will provide a gap between the loot and the gate of 10 mm on each side. Cut the edges at an angle of 450.

You can take a 25/40 profile for the middle jumper, its length should be 900 mm, it will be inserted inside the frame, so the width of 2 profile shelves is subtracted from the total length of the workpiece, in this case it is 80 mm.

You will need 2 hinges with an outer diameter of 30 mm and 4 steel plates 5 mm thick and 40 mm wide. The hinges must be disassembled and the inner surfaces well lubricated with grease or other grease, then assembled. Loops are best purchased with balls.

Plates are laid out on a flat surface and grabbed to each part of the loop from different sides. That is, if a plate is attached to the part of the loop with a hole from the outside, then on the counterpart, the plate is placed to the inside.

Welding is mandatory on both sides to ensure penetration of the root of the seam. After the first pass, it is necessary to beat the slag and weld the second pass. At the root, welding is performed in one pass.

Tools for the job

When all the main details of the gate are ready, you should decide on the lock and handles. If necessary, it will be necessary to weld brackets for attaching the handle from the inside.

• welding machine;
• electrodes for welding steel grades MP-3 or ANO-21;
• hammer, sledgehammer;
• protective clothing and welding mask;
• building level or a simple plumb line;
• trowel or spatula;
• several pipe sections, 1000 mm long for lintels when concreting pillars;
• concrete mortar;
• for the installation and welding of the hinges, embedded parts are prepared to provide gaps between the gate, the hatch and the floor.

Having prepared all the materials and tools, proceed to the manufacture and installation of the gate.

Installation and concreting of pillars

Based on the size of the opening, mark the installation sites of the pillars and make a hole in the ground with a hand drill, 80 mm deep. Then the profile is lowered into the holes, set strictly in a vertical position using a level or plumb line.

Special attention should be paid to this operation. The correctness of the entire installation of the gate depends on it. The pillars are fastened together with spacers and additionally each with jibs, poured with concrete, not forgetting to compact it when pouring. Now the concrete needs to be allowed to harden for a day.

Frame welding

Welding can be done first, and then poles can be placed, but vice versa. It does not take much time to weld the structure. On a flat surface lay out the standing parts and jumpers.

Put them on the level. Connect the stand and top jumper. Put 2 tacks on each rack from the outside and side. In the same way, grab the bottom part.

Measure the diagonal with a tape measure. A skew of 2 mm is allowed on the side, but it is better to do it without skew. Having set the diagonal, they grab it from the outer end surface of the joints. Mark and grab an additional structural strut. It should be flush with the surface of the uprights.

Scald the entire structure from all sides. The front side of the gate, on which the lining will be attached, is cleaned with a grinder. All other joints are beaten with a hammer and the quality of the welding seam is checked.

With large pores, these places are scalded again. Now you can clean up the uneven joints a little without breaking the seam. The wicket structure is ready.

It is necessary to weld the hinges on the wicket frame. This can be done when hanging it on poles, but welding in the lower position will provide a better seam.

For welding, mark the same distance from the edge of the structure, set the hinges coaxially to each other and the gate, grab them in several places. Once again, check the correct installation of the loops and boil them on both sides.

Hanging on poles

After allowing the concrete to stand, proceed to the installation and fastening of the street door. Remove spacers from loot. With the help of mortgages, the position of the gate between the pillars is set in compliance with the gaps.

From below, to prevent rubbing when the structure sags, a gap of 100 mm is made. This will keep the yard ventilated and prevent chafing. Check the correct installation in all planes and start welding the loops.

The plates on the counterpart of the loop are placed on the pole. Now follows from all sides of the plate. Remove embedded parts and check the operation of the gate. It should work easily without scuffing.

sheathing

If you sew up the gate with mesh or rods, they should be fixed before installation on the poles. When laying a sheet of corrugated board, it should be fixed after welding. The corrugated board is fixed on self-tapping screws, the caps of which are covered with decorative overlays.

Without high-quality welding, the gate will not last long. For reliability, be sure to check the filling of the seam with melt metal.

Before welding, once again check the correct installation of the part or the structure as a whole. Take your time.

Before sheathing with sheets of corrugated board, be sure to degrease all surfaces and go through first with a primer, and then with paint that matches the color of the decorative coating of the gate and fence.

Having correctly and efficiently completed all the welding and installation of the gate, you gain invaluable experience in the manufacture of frame structures.

Such a seemingly simple matter, how to weld hinges on a gate, often turns into a complex problem. It is much easier for many to weld a geometrically correct gate frame and gates than to install the finished structure in place and ensure that it works normally. In fact, this work is really not difficult, but it requires the utmost accuracy and accuracy, as well as knowledge of some nuances.

The result of inaccuracy can be distortions and jamming of the valves Source www.stroyzabor.ru

The choice of loops and their number

If it is decided to use welded hinges for installing the gate, then you can choose from several types:

• the simplest and cheapest option is a split cylinder with a rotating axle in one part and a cap cavity in the other. Such hinges need periodic lubrication, without which they quickly begin to creak;
• the most popular are hinges of the same design, but improved with a ball or bearing, on which the axis rests. They can be either two- or three-section;

Source dekoriko.ru

• another option is the same loops with metal plates welded to each part.

For reference! Welded loops most often have a circular cross section and, when assembled, resemble a cylinder. But their cross section can also be drop-shaped, with a sharpening along the walls. The shape does not affect the performance of the products in any way, it is chosen solely on the basis of ease of installation: it is easier for someone to weld one, for someone else.

However, it is not enough to know how to weld the hinges to the gate - first you need to calculate the load on them and decide on the quantity. This is easy to do if you know the weight of the valves.

Hinges without plates can withstand a maximum of 400 kg, depending on their diameter and length and thickness of the metal. And hinges with plates that take on part of the load are designed for more impressive weight - they can withstand up to 600 kg.

Knowing the calculated load on the hinges and the weight of the structure, you can determine the required number of them. Of course, there will not be less than two per sash. And in the case of heavy gates, the number of canopies is increased to 3 or 4. An additional loop is installed just below the top one, which bears the main load.

3 loops are often placed on massive insulated garage doors Source dekoriko.ru

By the way, you can also strengthen ordinary loops yourself by welding plates of a suitable size cut out of thick metal to them. The weld must be continuous.

Hinge welding technology

Before talking about how to weld hinges on the gate, it is worth dwelling in more detail on the conditions necessary for their normal operation.

Even if the load is calculated correctly, the hinges may not be able to cope with it if their position deviates even slightly from the vertical. They will wear out quickly. And the second point: there should be a small gap of 1-2 mm between the hinge body and the support post so that the metal parts of the post and the counterpart of the canopy do not touch and rub against each other. The same gap must be left on the side of the sash.

Video description

To understand what is at stake, watch the video

The nuances of installation on supports of different sections

The supporting posts on which the sashes are hung can be round, square or, less commonly, rectangular. There is a difference between how to properly weld the hinges on the gate to round posts or supports from profile pipes.

• If the profile pipe has even edges without bends and distortions, then it will be easy to cope with the task of how to properly weld the hinges on the gate to the square posts. They are installed on the outer plane of the support.

Source distroy.ru

• In the case of a circular support, you must first decide in which direction the sashes will open. Then they find the most protruding line (the middle of the column relative to the opening) and retreat from it a few millimeters outward - in the direction of plowing. 5-6 mm is enough for the gate or gate leaf to move smoothly and without jerks around the axis of the canopy. Since it is more difficult to weld hinges on gates to round posts than to square ones, here you need to be especially careful and attentive, maintaining the same indent for all loops.

Installation and welding work

Experienced welders recommend that you first weld the canopies to the doors, laying them on a flat horizontal surface. A half in the form of a hollow cylinder is welded to them, and subsequently a counterpart with a pin (pin up) is welded to the supports. Recede from the top and bottom edges by about 15 cm.

Source www.chipmaker.ru

Then the sash with welded canopies is installed in the opening on stands that provide the required distance to the ground, and rigidly fixed with clamps, tongs and other devices. They do this so that it stands strictly vertically, and there is a gap of 5 mm or so between it and the support. To do this, use a laser level or a plumb line, and spacers of the desired thickness are inserted between the elements.

Other craftsmen prefer to first expose the gate, and then weld the hinges to both it and the post. There is no big difference, everyone does as he pleases.

Advice! Installing the gate so that the leaves exactly match in level is quite difficult. So that they do not move during operation, they can be temporarily connected to each other by grabbing them by welding through a jumper.

Another option is to make the upper and lower ribs of the frame solid in the manufacture of sashes and cut them after hanging them on hinges. Source sqezo.ru

Now about how to properly weld the canopies on the gate. The sequence of work looks like this:

• around the loops from above and below, a wire 1.5-2.5 mm thick is wrapped and twisted to form a gap between it and the welding plane. You can put matches or other objects of suitable thickness, but they fall out, move or break, which is very inconvenient;
• on the supports mark the attachment points of the canopies and apply an even long bar or a profile pipe to them. Fix it in level, ensuring a vertical position.

Video description

See how it looks in this video:

• loops with wound wire are pressed against the bar and against the pole and also fixed in a vertical position;

Important point! The mass cable of the welding machine is hooked to the part of the canopy that will be welded. If you install it on a support, then as a result of resistance welding, the halves of the loop can interlock with each other.

• loops are welded to the supports at 2-3 points;
• in the same way, they grab the second (upper) part of the loops to the frame or leaf of the valves;
• when the tacks are frozen, the gate is checked for opening - they should swing open 180 degrees without jamming or warping;
• if everything is in order, the sashes are closed again, fixed and the hinges are welded to the finish with a continuous seam from the bottom up;
• cooled seams are cleaned with a hammer from scale and grind with a grinder to give a more aesthetic appearance. But this work must be done carefully so as not to damage the joint.

After painting, the sanded joints will become almost invisible Source i.ytimg.com

Do not open the gate until the welds have completely cooled down and gained strength.

Conclusion

You can also hang metal gates on other canopies, which are fastened with screws or nuts. But the welded method is more reliable and durable, especially if you know how to properly weld the hinges on the gate and clearly follow all the requirements regarding the technology of their installation.

The functionality of the gate is based not only on their reliable locking, holding power loads and strength, but also on convenient opening / closing. Ideally, the last two characteristics, as well as the absence of gaps between closed gates, are achieved using high-quality welded hinges. Anyone who knows how to use electric manual arc welding will be able to weld the hinges to the gate with quality if they know how to do it right.

Opening and closing the gate without squeaks and jerks is the best that the correct installation of the hinges can give. How to achieve this? First, choose the right way to install the hinges for a particular material of the gate and support posts. Metal, wooden, corrugated or polycarbonate gates, metal, wooden, concrete, foam concrete, brick, stone or cinder block poles: in any case, it will be best to choose ball hinges. In the cavities of such loops there are balls, which greatly facilitate the movement of the gate.

First you need to find out how the loops on the gate work in pairs: on one gate leaf, both loops must be on a mentally drawn straight center line. That is, after the completion of high-quality work, the lower loop should be exactly under the upper one, and both loops should have an even axial location in space. With such welding of the hinges, the weight load of the door will be evenly distributed on the hinged supports.

Beginning of work

The cylindrical shape of the hinges often makes inexperienced welders wonder: “Does this even cook?”. Boiled. Loops made from a hexagon or a tetrahedron are actually more difficult to cook. According to the correct technology, the loops are first welded to special plates. It is desirable to do this on a flat horizontal surface, for example, on an anvil (at the same time, you can attach the "minus" of the welding machine to it). An integral requirement: it is necessary to weld the plates to the hinges with a continuous seam.

It is not difficult to choose the right size platter. We take into account the weight of the gate and the strength of the material from which they are made and determine by eye how long the welding seam can withstand the weight and not allow the door structure to deform. Platiki organize a convenient working "platform" for welding, and they also serve as distribution plates for the door leaf, which does not allow the latter to "break" even with the overall heavy weight of the door structure.

Gate installation

It is necessary to carry out welding of loops with already welded plastics permanently, having previously placed the gate in the “native window”. That is, the gate will have to be fixed “idle” and reach their required position even before the start of welding. The position of the doors must be checked and rechecked as many times as the average first grader knows the numbers - at least ten.

Welding

After a thorough check of the location of the gate, pre-measured and marked fields for plates, it is possible to start welding work from the lower hinges on the poles. Vertical seams are the most difficult job for a welder. But thanks to the plates, even an inexperienced welder can handle them. When one bayonet part of the hinge on the sash is welded, it will be possible to use the laser level to verify the correct location of its axis and to determine the exact location of the second bayonet hinge.

Completion

After carefully welding the bayonet parts of the loops on the pole, they will need to be baited with the plug-in upper parts of the loops immediately with the balls. Then press the baited part as tightly as possible to the door leaf and continue welding.

At the end of welding, the seams can be processed with a grinder.

This technology has been successfully used by all door installation services for a long time. It will not be difficult to do it yourself if you have welding skills and the necessary equipment with consumables:

• metal door hinges;
• Records / plastics;
• Welding machine;
• electrodes;
• Locksmith's hammer;
• Welding mask, gloves and overalls;
• Bulgarian.

Please note that the gate must open outward, because if the gate opens inward during heavy snowfall in winter, this can be a big problem!

Hinge installation example

Gate installation is a complex and painstaking process. The density of the clamping of the sash, the reliability of the design depends on the correctness of its implementation. One of the critical stages is the installation of rotary elements. Before welding the hinges to the gate, it is necessary to select the appropriate model and adapt it according to the characteristics of the finished structure.

Selection and preparation of loops

For a relatively small sash weighing up to 200 kg, ordinary cylindrical hinges are suitable. Quantity per side - from 4 or more. It is important to correctly calculate the load. To turn the pin in the factory models, a bearing is provided. If it is not there, you need to install a steel ball.

The essence of modernization is to increase the area of ​​contact of the loop group with the plane of the gate and support pillars. To do this, do the following.

1. Choice of plates. These are plates that provide reliable fastening of the loop to the canvas.
2. The size of the plates depends on the weight of the sash. The thickness must be at least 3 mm.
3. The length of the plates should not interfere with the normal operation of the sash.

Upon completion of this process, you can begin to assemble the structure.

Method of fastening to the gate

The hinges are welded onto the finished sash. They must be fixed on the base frame, installation on metal sheathing sheets is prohibited. The best assembly option is with the supporting pillars installed. There may be difficulties with fixing the gate in the working position. Additional subconstructions can be used for this.

• gap between the support post and the sash frame - up to 5 mm;
• pre-marking is done, taking into account the fact that the hinges must be on the same axis;
• part of the loop group with the pin is located below, its direction is at the top;
• first, a test welding is made for a maximum of three points, it is recommended to start from the bottom loop;
• after that, the correct operation of the gate is checked - they must open and close freely, the gap is controlled, there is no spontaneous movement of the leaf, regardless of its position;
• final welding of the plates along the perimeter, after cooling - descaling and surface cleaning.

Over time, the sash may sag or change its position. If the gap does not compensate for this, it is necessary to redo the mounting assemblies. To solve this problem, it is recommended to use hinges with an adjustment function.

Materials and tools

You need professional tools to get the job done right. can be any, it is important that it provides enough power to form an arc. It depends on the thickness of the metal and the diameter of the electrodes used.

In addition to the welding machine, you will need the following tools and consumables:

• protective mask of the welder;
• measuring tool: ruler, tape measure, building level;
• grease for hinges - grease or a composition similar to it in properties;
• grinder will be required to clean the welds and dismantle the incorrectly installed loop group.

Support poles are best made from a profile pipe of square or rectangular section. This will ensure the reliability of the design and facilitate the process of mounting the canvas.

The reliability of the gate directly depends on compliance with the rules of their installation technology. The support poles are attached first. If the canvas will be made independently, the dimensions of the frame will be determined only after the first stage. It is important to remember the technological gap.

In the lower part, the distance to the ground surface must be at least 100 mm. This is necessary to compensate for the possible subsidence of the structure. As a sheathing material, you can use corrugated board. For reliable fixation of the corrugated board, additional stiffeners are welded. Additionally, you can provide a small gate. An alternative is to make it separately, if the width of the mounting opening allows.

After welding the hinges, the surface is cleaned of rust, a layer of primer and paint is applied. To avoid extraneous sounds when opening, the hinges are lubricated with grease.