sakurama
Adventurer
This is a great armchair fabricator experience showing the process on a nice ladder. Helps with all the “That welded thing’s so simple.m, why’s it cost so much? I could just make my own.”
Yeah, I'm very susceptible to that sort of thinking but I tend towards the "how can I make it better or more personal?" and I know it will not be worth it on a time/money function but for me it's always a learning experience. I wanted to improve my aluminum welding skills so what better way than to build a ladder and roof rack all from aluminum!
![i-qwWd59T-X2.jpg](https://photos.smugmug.com/photos/i-qwWd59T/0/eeed0ca9/X2/i-qwWd59T-X2.jpg)
After checking the fit up (it was good) I set about finish welding the rungs in. The bottom rung was just a bit twisted out and while I saw it early I decided to not mess with it as fixing it was going to be impossible and replacing it was not worth it. I considered trying to fit the tube by hand but as I was feeling cocky with my aluminum welding I figured I'd leave it and see if I could fill the gap.
![i-NVdpkrW-X2.jpg](https://photos.smugmug.com/photos/i-NVdpkrW/0/daa38911/X2/i-NVdpkrW-X2.jpg)
It wasn't a problem. In fact I was finding that I could take my time and really pay attention to the weld and how much the aluminum wet out, how much filler changed the profile of the bead, how much I needed to let off between pulses.
![i-cf9MZH3-X2.jpg](https://photos.smugmug.com/photos/i-cf9MZH3/0/eae4bb32/X2/i-cf9MZH3-X2.jpg)
Today was one of the best welding days I've had. I've always loved welding and machining aluminum but today I felt like I turned a corner.
![i-2fTkHvB-X2.jpg](https://photos.smugmug.com/photos/i-2fTkHvB/0/df1c6a6b/X2/i-2fTkHvB-X2.jpg)
Right up to the end where I attempted to close up my first tube and forgot that I'd not put a vent hole in. If I'd been thinking ahead I'd have drilled under where the tube went so that it would vent into the long vertical tube. But I didn't. As you attempt to close off a tube the air inside gets super heated and expands and if you don't have a place to vent it will explode out - which it did.
![i-2fxzXCb-X2.jpg](https://photos.smugmug.com/photos/i-2fxzXCb/0/4181bc0e/X2/i-2fxzXCb-X2.jpg)
It cleaned up fine and I drilled some holes in all the rungs and I'll just put a dab of glue or epoxy on them before I paint it.
![i-n9wkF6Z-X2.jpg](https://photos.smugmug.com/photos/i-n9wkF6Z/0/9622e4f0/X2/i-n9wkF6Z-X2.jpg)
![i-Bzxm2xH-X2.jpg](https://photos.smugmug.com/photos/i-Bzxm2xH/0/04e734c5/X2/i-Bzxm2xH-X2.jpg)
![i-2xqTSXS-X2.jpg](https://photos.smugmug.com/photos/i-2xqTSXS/0/d3431eca/X2/i-2xqTSXS-X2.jpg)
![i-zPBbbgj-X2.jpg](https://photos.smugmug.com/photos/i-zPBbbgj/0/0e64468e/X2/i-zPBbbgj-X2.jpg)
Once all the rungs were welded into place I fit the ladder to the rail again and decided to clearance a small amount for the vertical part of the rail. This should give it a little more purchase and a tighter clamp.
![i-jg9MCX2-X2.jpg](https://photos.smugmug.com/photos/i-jg9MCX2/0/6b6fc177/X2/i-jg9MCX2-X2.jpg)
The block was radiused to snug into the seam and then drilled through for 8mm flat head bolts.
![i-DdNDsXp-X2.jpg](https://photos.smugmug.com/photos/i-DdNDsXp/0/e7edcd7d/X2/i-DdNDsXp-X2.jpg)
![i-qLBCZMm-X2.jpg](https://photos.smugmug.com/photos/i-qLBCZMm/0/f307c71d/X2/i-qLBCZMm-X2.jpg)
I'm super happy with the fit up so far - it's very tight.
![i-75Hg7mp-X2.jpg](https://photos.smugmug.com/photos/i-75Hg7mp/0/c9a8750f/X2/i-75Hg7mp-X2.jpg)
![i-pSjSk6Q-X2.jpg](https://photos.smugmug.com/photos/i-pSjSk6Q/0/84f62511/X2/i-pSjSk6Q-X2.jpg)
After all the clamps were tightened down the ladder was rock solid. Zero movement or flex. I was able to bounce the entire van by jumping on it. I am very happy with how burly it is - much better than I expected. I'm going to get some more bed liner tomorrow and get it painted and then start to think about the roof rack.
I will say that the ladder really changes the van. Being able to get onto the roof so easily changes the whole feel and adds a lot of practicality to the van. Now to think about the platform.
Gregor