Results 1 to 14 of 14

Thread: Wood Berm Repair & Upgrade Progress

  1. #1
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default Wood Berm Repair & Upgrade Progress

    We're getting nearer to finishing repairs to the #3 berm on the South Down trail. Goal being to have it rideable by the Abermination MTB Race on 5/4.

    The wooden decking is being replaced with expanded metal grating for longevity. The metal riding surface will consist of ten bolt together panels and attach to the existing wooden structure.

    We finished bending and cutting out the various pieces needed for assembly Sat. and are currently welding them together into panel assemblies. We were able to assemble one simple curve panel as a test without major issues. The remaining panels have complex curves and may be more challenging.

    Currently creating a welding fixture for the remaining nine panels to speed up assembly. The time consuming part of this process will be welding out each panel since there are +100 small welds needed to attach the expanded metal to the frames. Focus will be on tacking panels together and then finish welding.

    If anyone wants to help with the final welding of these panel sections and has their own welder & necessary metalworking gear let me know and we can make arrangements.


    Simple Curve Test Panel | Weld Detail



    All Panel Sections Assembled | Complex Curve Panel Weld Fixture
    ⚒ Trails don't build themselves. ⚒

  2. #2
    Join Date
    Sep 2022
    Location
    LeClaire Iowa
    Posts
    38

    Default

    I got a small 110 welder with gas bottle with gloves, helmet, and jacket. Is this something I need to bring equipment over.

  3. #3
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default

    If you want to pick up a panel and take it with you that would probably work best. Don't have one fully assembled yet, but will let you know when one is ready. I'm using flux-core wire in my welder. Not too concerned with cosmetic welds; just need to be strong and numerous.
    ⚒ Trails don't build themselves. ⚒

  4. #4
    Join Date
    Sep 2022
    Location
    LeClaire Iowa
    Posts
    38

    Default

    Sound's good let me know when you want me to pick up some items and I can get them back here and weld some up.

  5. #5
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default

    Planning to install finished panels on Friday afternoon starting at 4pm. Have 4 assembled and waiting for weld out which may already be claimed.


    Pre Assembled Complex Curve Panels | Test Fitting
    ⚒ Trails don't build themselves. ⚒

  6. #6
    Join Date
    Mar 2010
    Location
    Davenport
    Posts
    182

    Default

    I can also help with welding if needed. Could pick up panels today or Wednesday. Truck is down for maintenance tomorrow.

  7. #7
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default

    Great! Should have 2 more panels ready to go for pickup tomorrow.
    ⚒ Trails don't build themselves. ⚒

  8. #8
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default

    7 of 10 panels are assembled and vouched for final welding. Should be able to get the rest tacked together by tomorrow. May start install Thursday evening after 5:30pm to be safe given we have enough panels back.
    ⚒ Trails don't build themselves. ⚒

  9. #9

    Default

    I may be able to help. I do not have a truck but I do have a 110/220 mig welder with gas, angle grinder and ppe with nowhere to hook it up. I live in an apartment and they don't take kindly to me welding in the kitchen. I would have to get a new roll of wire, and probably some tips. This has all been sitting for a few years. If you need some last minute help, and have some spare electricity, I have a few extra hours this week.

  10. #10
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default

    Bryan, thanks for the offer but I think we're good at the moment. There is one panel left to assemble and it has been claimed for final welding. Will let you know if anything changes.

    Weather is looking wet for Thursday so sticking to install on Friday. I'm taking Fri afternoon off and will be out mid afternoon (2ish?) to start. There are a few small drainage issues that would be good to take care of on the Upper South Loop if we have enough people (I'll have dirt moving tools). Battery powered drill/impacts, metal drill bits, & battery angle grinders will be useful for berm metal install. Will need to drill holes in metal frames for mounting panels.
    ⚒ Trails don't build themselves. ⚒

  11. #11
    Join Date
    Sep 2022
    Location
    LeClaire Iowa
    Posts
    38

    Default

    What size drill bits are needed for the metal frame drilling?

  12. #12
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default

    Frame bolts are 3/8" so a little larger bit (7/16") for the holes to take care of any misalignment and 5/16" for the construction lags. If I have time, may pick up some spares just in case. Step-bits would be ideal if you have a set.

    Mesh on all panels has been fully welded and 4 panels need a few brackets welded on. Will get that taken care of tomorrow morning. Otherwise everything is ready to go for install.
    ⚒ Trails don't build themselves. ⚒

  13. #13
    Join Date
    Sep 2022
    Location
    LeClaire Iowa
    Posts
    38

    Default

    Owen and I should be over shortly after 3pm. Would be sooner but schools not out till 2:30.

  14. #14
    Join Date
    Nov 2008
    Location
    Hampton, IL
    Board Position
    Trail Steward - Illiniwek; Web Director
    Posts
    1,875

    Default




    Thanks again for all the help today! All panels are mounted and the feature is rideable. Heading out at 7am Sat. morning to tie up a few loose ends and raise a section of pavers on the inside of the berm. Had to raise a couple piers for better alignment of the panels which left some gaps along the bottom rail.
    ⚒ Trails don't build themselves. ⚒

Similar Threads

  1. [Trail Build Day] Dorrance Feature Building - UR Wood Berm - Sat 12/14 @ 9am
    By DH001 in forum Dorrance Forest Preserve [DFP]
    Replies: 1
    Last Post: 12-15-2019, 09:26 PM
  2. [Trail Build Day] Dorrance Feature Building - UR Wood Berm - Sun 12/8 @ 9am
    By DH001 in forum Dorrance Forest Preserve [DFP]
    Replies: 0
    Last Post: 12-03-2019, 10:17 PM
  3. [Trail Build Day] Dorrance Feature Building - UR Wood Berm - Sun. 11/24 @ 9am
    By DH001 in forum Dorrance Forest Preserve [DFP]
    Replies: 1
    Last Post: 11-25-2019, 07:21 PM
  4. [Trail Build Day] Dorrance Feature Building - UR Wood Berm - Sun. 11/10 @ 9am
    By DH001 in forum Dorrance Forest Preserve [DFP]
    Replies: 0
    Last Post: 11-06-2019, 11:08 PM
  5. Park repair stand
    By Byke Dood in forum Buy & Sell
    Replies: 0
    Last Post: 08-03-2009, 05:16 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •