S/S Hand rail-destortion control, need help

[bankswelding]

I am building my first set of S/S handrails. They are to be 20' long w/ no bends. I am using 304 S/S, top and bottom rails are 2" X 2" X .083 Sq tubing.
there are 2" X 2" X 1/8" post on each end and three more between those at 5 ft apart. The finished product will have 3/4" pickets (sq. tube) @ not more than 4" between.
I have problems with the rail "pulling" or bending from the heat of the weld. I have kept heat as low as possible, and use a min. of filler material.
Can anyone offer some techniques to help control this prob.?
Thanks,
Phillip

[Rocky D]

Tack the entire project up, then start at one end and weld each vertical member 100% before going to the next....the pickets weld the outside on both ends before doing the cross weld. It will look horrible until you weld the last one...then when it is all welded, it will be straight. It's important to have the heat gradually flow from one end to the other evenly...don't try to minimize the shrinkage by jumping around, that will only compound the problem, and you will end up with a snake. :eek:

[bankswelding]

Thanks Rocky D.
That makes sense, I was getting relly concerned and as a natural response I was thinking about "skipping" about.
I will put the info to work.:)

[Rocky D]

Hi Rocky,
What about the ends and posts which are 2" sq. tube?: the top rail and end posts connect with a 45 deg. miter joint. Do I need to follow a particular sequence when welding them?
Weld the outside corner first, then the flats starting from the inside corner to the outside corner the the inside corner across last.
Also, on the bottom, the posts go down and the bottom rail is butted against the sides of the posts. Because of the curvature of the corners of the sq. tubing there is a little gap which I will need to add some filler to. Is there a method or sequence of welding which would aid in controlling distortion on these?
No, you may have to do some straightening at the last, but SS is easy to straighten with a 5# rawhide mallet, or similar...rawhide mallets won't damage the steel, but will move it to where you want it.
Phillip
As long as you weld and draw the heat in one steady direction, the welds will pull against them selves and be straight when all is done. I tired to send this via PM but it wouldn't go.

[bankswelding]

Thanks again for the help. Sorry about the PM thing, I am still working on getting myself set up on the site.
Phillip

[bankswelding]

Rocky D,
The first of the 2 rails is complete. It turned out great! Thank you for your help, I couldn't have done it with out you.

[Skwerly]

Case in point on how cool these sites are! Good folks who help other good folks, man I'm in heaven!! The internet combined with nice people is a powerful tool indeed!!

Can you post pics of the project?

[Rocky D]

Rocky D,
The first of the 2 rails is complete. It turned out great! Thank you for your help, I couldn't have done it with out you.
Glad to help.