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Long precision-rolled helical stainless steel coil mounted on a welding stand in the Sons of Thunder shop

Manufacturing / Production Run

67 stainless burners, from prototype to palletized delivery

Shop · Manufacturing

67Stainless burners produced, plus additional parts
100%Within spec and tolerance, every unit repeatable
DeliveredPrototyped, produced, packaged, and shipped
  1. 01The challenge

    Heat Wagon needed a stainless steel burner built to a spec no shop they called would take on. The geometry was unforgiving: precision-rolled stainless, perforated bands, threaded ports, and tight tolerances that had to hold across not one part but dozens. They needed someone who could prove the process and then actually produce.

  2. 02Our approach

    We started at the prototype and refused to scale until it was right. We dialed in the rolling, perforating, and TIG-welding process until every dimension landed inside spec, then locked it down for production. From there we batched the work: rolled the stainless strip, cut and perforated the bands, prepped the threaded NPT nipples, and welded up repeatable burner cans, every unit matching the last.

  3. 03The result

    Sixty-seven finished burners plus additional parts, every one repeatable and within spec and tolerance. We didn't stop at the weld table: we shrink-wrapped them, palletized them, loaded the box truck, and delivered. The customer who couldn't find anybody to make this part now has a shop that can make it again.

“They couldn't find anybody to make this burner. We prototyped it, proved the process, and built 67 of them, then loaded the truck and delivered.”

— Sons of Thunder Welding

From the job

The work, up close

The Heat Wagon burner kit staged for assembly: rolled stainless strip, perforated strips, and threaded NPT nipples, cut and prepped in batches.
The Heat Wagon burner kit staged for assembly: rolled stainless strip, perforated strips, and threaded NPT nipples, cut and prepped in batches.
Laser-perforated stainless strips laid out in batch, every hole pattern identical down the run.
Laser-perforated stainless strips laid out in batch, every hole pattern identical down the run.
Two finished TIG-welded perforated stainless burner cans, side by side and dialed to the same spec.
Two finished TIG-welded perforated stainless burner cans, side by side and dialed to the same spec.
Finished burners shrink-wrapped, palletized, and loaded for delivery - we package them and get them to the dock.
Finished burners shrink-wrapped, palletized, and loaded for delivery - we package them and get them to the dock.
Detail of a finished burner can: the threaded NPT nipple welded into the perforated stainless body, TIG seam clean and consistent.
Detail of a finished burner can: the threaded NPT nipple welded into the perforated stainless body, TIG seam clean and consistent.

Let's build it

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  • AWS-certified welders
  • OSHA 10/30
  • Insured & bonded