May 2008 Edition

WELDING

Stitch-welding a Labor of Love

A truck manufacturer updated its welding equipment to continue producing its handcrafted pieces of art

Art and work. It’s hard to tell them apart at Rogue Truck Body, Kerby, OR. The products made at the company are considered art, no matter how mundane their use as truck trailers or other products.

At Rogue Truck, the team uses the same skill, detail, and finesse as any large-sculpture artist, because the transfer trailers for which the company is known are manufactured one at a time. Each trailer, made from light, durable steel, is special-ordered and cut, joined, welded, and painted to each owner’s individual specifications. The company even signs its pieces by deliberately leaving external welds visible using its unique stitch weld.

"Every trailer we build is handcrafted; a labor of love, both for us and the new owner," Ryan Lewis, shop foreman and weld team leader, said. "It’s not uncommon for customers to pull up a chair and hang out in the shop for the week to watch their new transfer being built."

Welding is integral to the firm’s success, and welding is performed at almost every stage of the construction process for the truck transfers, pups, and heavy haulers, which start at $80,000 and can climb to $250,000 – not including the truck.

Signed on the Stitched Line

Rogue Truck’s signature stitch weld was invented by company founder Keith Hill. He used standard MIG process on thin gauge steel, which he preferred because it let him create trailer boxes that weighed less and could haul more, putting more money in the driver’s pocket. But, he found the steel warped.

"Thin gauge material, combined with 14'- to 18'-long welds, led to steel warping, so Keith did what he does best – created his own solution," Lewis said. "That solution is our signature on every trailer box we build. Customers know it’s our product as soon as they look at it."

The stitch weld is created by the welder running a bead and pulling it towards him. He jumps out of the weld and backs up the torch. This keeps the heat more consistent across the surface and heads off warping. The clean weld looks like a tipped stack of dimes.

"Our stitch weld is our calling card. They’re all done manually and not ground off, so there is no room for imperfections," Lewis said. "We needed equipment that gave our welders the versatility and precision to ensure every weld is perfect."

This attention to detail, customer focus, and high-quality products are what have kept Rogue Truck’s customers coming to southwestern Oregon since it opened its doors 17 years ago. More than 40 percent of the work the company performs is high-end custom projects, including additions, such as aluminum tailgates, stainless fuel tanks, and stainless steel rails. The company also takes one-of-a-kind special requests such as a stainless steel box to hold a set of golf clubs or custom emblems.

"If our customers can think it, we can build it," Lewis said. "They spend more time in their trucks than their living room, so we want them to know they have the best equipment and it fits their exact needs."

A New Partner

The family-owned company investigated updating its welding equipment at both its Kerby headquarters and a second location, where it manufacturers and houses its own parts and supplies. The company needed welding equipment that provided versatility, adaptability, and ease of use by its team of 20 welders. Lewis turned to Rogue’s long-time partner, Industrial Source, an Oregon gas and welding supply dealer, for advice and guidance.

The Lincoln machines have directly contributed to a 30 percent productivity increase

"With all welding performed by hand, it was critical the new equipment stand up to the demands and the high level of quality the company is known for," Bruce Sampson, of Industrial Source, who worked with Lewis and Rogue, said.

Sampson partnered with The Lincoln Electric Co., Cleveland, and its local technical sales representative Al Steiner, to provide Rogue with a Lincoln Power MIG 255 machine for testing. The welder was on-site for a couple of weeks, while Lewis and his team put it through the paces.

"The Power MIG did what we needed," Lewis said. "Al and Bruce were on-site, helping us make adjustments and answering questions. They provided the same level of hands-on customer service on which we pride ourselves, serving as a partner, not a vendor."

Rogue’s machine trial led to its purchase of 17 machines, including Power MIG 255s with Magnum spool guns, Invertec V350-Pro machines with LN-10 wire feeders, and a Precision TIG 275.

The Process of Building a Truck

All raw materials enter Rogue Truck’s manufacturing process through its second facility, which houses parts and handles forming, fabricating, machining, and some assembly. The truck parts are made from a light, durable, structural steel. The steel is designed to let heavier loads be carried and still remain within legal limits.

The company cuts the sheet plates into size using a 20' hydraulic sheer. A hydraulic press break is used to form the floors and walls of each trailer. A plasma cutter cuts a variety of the 5,000 different parts used by Rogue.

The first step is to build the floor of the truck box. The floor is placed upside down on a table. The main frame structure is tacked and MIG welded using the Power MIG 255s. The box is flipped right side up and passed to the box builder. The walls and front are created, jigged up square, tacked, and welded.

The majority of Rogue Truck’s boxes are then affixed with a skirt, which can be made from polished stainless steel, and top rail – both of which are typically TIG welded with the Precision TIG 275. The trucks then head to the tailgate department.

At each step, Rogue Truck’s team double-checks the work against a build sheet, unique to each customer and trailer. The build sheet is reviewed and all details are cross-checked before sent to the sandblaster.

The sandblaster preps the trailer for paint, as well as removing any remaining weld spatter. The painting department then takes over, and the transfer trailer is primed and painted.

"And unlike our competitors, we don’t outsource our paint work. We do everything in-house," Lewis said. "This gives us great control over delivery time and quality."

According to Lewis, the Lincoln machines have directly contributed to a 30 percent productivity increase for the company. Currently, it takes about a day to tack a box, whereas previously it took a full day-and-a-half.

Because of the success Lewis and his team found with the Lincoln welders, the company purchased five more machines for its Southern California service facility in Lake Elsinore.

"The Lincoln welders let us deliver our product faster without making one compromise in quality," Lewis said. "They’re easy to train our guys on, they’re always up and ready to go as soon as we are, and they deliver a solid bead every time." The Lincoln Electric Co.

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