knoba
...break a leg!
- Messages
- 863
- Location
- Sussex, England
Please, please, please! Don't force me to reveal, the techniques, & all the gritty working details of this project... all-right then... I'll tell you all about it...
The day began much like any other; I awoke to find myself smothered in sardines, ...no, wait, wasn't that yesterday?
Anyway, it's been a long while since I did a project thread. This one's an epic. Let's get down to it...
The job is to furnish an absent cap, for a post, as part of the frontage (railings) to a Victorian property.
Voilà...
No CAD this time, infact: no formal planing at all. It's an aesthetic piece; original iron work is quite rough (sand casting). I want the piece to blend in. I reasoned on; making a basic frame from EA (equal angle), & then fabbing up a 'pyramid form', to skin over it out of 3mm sheet, and then see what the go is from there. The square metal cap needed to be approx. 9" wide with the internal aperture of the pillar @ 7" (hence the mental jump to 1" EA). Job is at another property. I'll be using my inverter in AC MMA mode, with white box 6013's, for the welding and some old hand tools to help achieve that 'seen better days' look.
Closer look...
Finished job...
I have lots of 3mm x 25mm equal angle, for the framework, but I've got no suitable sheet/plate around. A local fabricator sold me approx. 500mm x 900mm x 2.5mm sheet, with a slight surface bloom, for £3 cash.
First job was to clean it up, a bit, with a zirc disk...
Checking what I got to work with; square, surface defects, etc. & marking out...
Raising the sheet off the bench with 2x2's ready for cutting...
I've cut out the four sections that will form the pyramid shape...
Ball park...
All dressed & de-burred...
The day began much like any other; I awoke to find myself smothered in sardines, ...no, wait, wasn't that yesterday?
Anyway, it's been a long while since I did a project thread. This one's an epic. Let's get down to it...
The job is to furnish an absent cap, for a post, as part of the frontage (railings) to a Victorian property.
Voilà...
No CAD this time, infact: no formal planing at all. It's an aesthetic piece; original iron work is quite rough (sand casting). I want the piece to blend in. I reasoned on; making a basic frame from EA (equal angle), & then fabbing up a 'pyramid form', to skin over it out of 3mm sheet, and then see what the go is from there. The square metal cap needed to be approx. 9" wide with the internal aperture of the pillar @ 7" (hence the mental jump to 1" EA). Job is at another property. I'll be using my inverter in AC MMA mode, with white box 6013's, for the welding and some old hand tools to help achieve that 'seen better days' look.
Closer look...
Finished job...
I have lots of 3mm x 25mm equal angle, for the framework, but I've got no suitable sheet/plate around. A local fabricator sold me approx. 500mm x 900mm x 2.5mm sheet, with a slight surface bloom, for £3 cash.
First job was to clean it up, a bit, with a zirc disk...
Checking what I got to work with; square, surface defects, etc. & marking out...
Raising the sheet off the bench with 2x2's ready for cutting...
I've cut out the four sections that will form the pyramid shape...
Ball park...
All dressed & de-burred...