Other end o the gussetsLooks like two inches of weld per post or 4 grand in Screwdrivers world. How does that add up to 500m? More like 100m...
Because they are driven into the ground with a GPS guided machineWhy can’t those posts be welded up on the bench then installed on site?
Ask to the customer not to meAren't those stays (gussets?) normally bolted as per that photo? Also you mention removing zinc so I assume they are galvanised - another can of worms as you are then into more clean up, consumables, grinder leads/batteries required and possibly even galv spray paint afterwards to restore.
The rate of 200 posts a day seems very high to me as well. Offer to do one or two to begin with, make sure you the customer is happy with the end result and you both know how long it will take (any dodgy bits of ground with poor access?) and then you can think about costing it.
Ask to the customer not to me
He's a retired engineer way better not asking or things will become much more complex .Customer sounds a bit clueless , don't believe the customer is always right. If they can't explain why they want to weld a connection that should be bolted I would run, not going to end well.
I don't know really .who sets them up for welding
I don't know really .
But the vertical ones are driven by a tractor attachment which is controlled via GPS
my mate has a post knocker attachment for his tractor. He uses a basic GPS device to keep track of things.
only does wooden posts
Nothing to cut just remove little bit of zinc 10cm bead (2 weld joints)
Welder on the truck
Let's say 70 post each day might be more possible
Estimated little bit more because also thinking to do the job with a friend who is a good fabricator .