In the photo the wear edge is not finished, but only ready for fitting.
- Angle iron from a bed frame
- 1/4 inch bolts and nuts
- Angle head grinder, cutting and grinding wheels
- Measuring and marking tools
- Vise-Grip pliers
- Keyhole saw with a fine blade
- Flux core wire feed welder and 230 volt stick welder
Step 1: Make flats from angle iron
Step 2: Mark and cut the shovel edge to make it straight
Then I cut on the marking line with a fine saw. (Second photo. The saw is from a previous Instructable I did. In this Instructable I showed how I fitted a blade from a common reciprocating construction saw.) Use a file as necessary to make the fit between the edge of the flat and the front of the shovel fairly close.
Step 3: Cut and weld shorter mounting pieces
Step 4: Making holes in bed frame steel
I decided to make holes by plug welding with a high amperage setting on a 230 volt stick welder using a 1/8 inch welding rod. (See the second photo.) 120 amps would be a reasonable setting for normal welding with a 1/8 inch rod. I set my welder to about 175 amps. (See the left amperage scale for the "High" range readings. The wheel kit on this welder is from a previous Instructable I did.)
Plug welding involves using the tap method rather than the scratch method to strike an arc where you want the hole to be. A little practice is necessary, but the idea is to push through the molten metal in the weld puddle to make a hole, and do so without sticking the rod. This results in a hole the diameter of the welding rod. I wanted to attach my wear strip with 1/4 inch bolts, so I used plug welding to poke around the edge of the original hole and enlarge it. I used a grinding wheel to remove any rounded ridges from the molten metal. (Plug welding is handy if you need to mount an electrical outlet box on a steel beam. Strike an arc and push through the box so a molten pool forms in the surface of the beam. Then back the arc out so the hardened metal overlaps the outer surface of the outlet box's surface.)
Step 5: Drill mounting holes in the plastic
Step 6: Make strain relief washers
Because the plug weld method of making holes is not completely precise the holes in the mounting pieces for the two left bolts and washers shown here were a little too far forward and I had to position the strain relief washers horizontally instead of vertically as I would have preferred.
Go back to the previous step and drill a hole for another bolt. Add a strain relief washer and bolt. Secure the nut. Repeat this process until four bolts and four strain relief washers have secured the four mounting pieces.
My bolts are too short for a lockwasher or a locking nut. The plastic compresses a tiny amount. If the nuts loosen, I will tack weld the nuts onto the screw threads to lock them in place.