- Thread starter Helder
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Helder
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Yeah, I thought I'd start with the small hobbyweld bottle (have a supplier right around the corner) and see how long that lasts. I designed the cart to have enough room for the diameter of the bigger bottle. Could lift a fair bit of weight before lockdowns shut down all the gyms so I figured I'd be alright. Never held one of the bigger bottles though so we'll see.
Thanks for the feedback everyone.
Thanks for the feedback everyone.
trust me ,,, removable now ,,, it will save you doing the paint again in the future should you change bottle size .
You can thank me later ,,, lol. great job though looks like it will end up very tidy indeed.
Helder
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Friday 12/02/2021
On Friday I took a longer lunchbreak and used the good weather to cut the flat that will form the support plates for the wooden bottoms in the layers that need them, and the ends for the axle:
In the evening I marked up the positions for the holes:
Which I then drilled in the shed. Judging by the heavy package I had to carry up the stairs the other week I am getting a pillar drill for my birthday, but for now we'll have to do it by hand (with my grandfather's drill!)
This worked fine with my m4.5. It got a little trickier when moving up to the M10.
Sometimes one has to make do...
The cobalt is great, but at that speed it does bite down if you're not careful and my holes were... less than spot on.
Given the fact the axle is stationary and I'm not too concerned about the handling of my cart I'm no too concerned
So the Friday went pretty decently.
Saturday 13/02/2021
Saturday was quite windy, so I made a little makeshift workspace with wind shielding and welded in-between gusts of wind.
Figured out the settings for the 3mm plate, and tacked everything up.
Welded everything on. Still a little erratic but I'll keep on practicing. Tried welding some of the inside corners as well, but because of the flat meeting the box section on the rounded corner I have sort of a gap between them, and everything is very tricky to reach. Rather than just spamming molten metal al over the place I figured the welds I did on the bottom would easily support the loads it'll have to bear.
Then put on the end caps for the axle. The weld looks pretty I think. It looks a bit cold because of how raised it is, but I could see it melt into the material and it definitely penetrated well. Maybe my wirespeed was a bit high for this join as I used the same speed I did for the flats against the bottom of the box section (2 to 3mm lap joint at 5.5/10 wirespeed)
I then cut the triangles that will be used in the inside corners of the upright, and wanted to use my newly acquired marking fluid to mark out the radius for grinding off. It came with sort of a felt-tip pen cap that didn't work very well.
Being a bit thick I decided to squeeze the bottle...
Lets just say I was grateful for a few things.
Grateful I was gearing safety goggle, because I reckon that stuff is not pleasant in the eyes.
Grateful I did this in the shed, not on the dining table (girlfriend would have killed me)
And grateful said girlfriend had nail-polish remover so I no longer look like a smurf...
And with that I was done for the Saturday.
Sunday was a bit of a loss. All rain and wind. I did manage to drill the holes that will be sued to attach the welder to the top section.
Planned to use my HSS hole-saw (only used for plastic so far) to make large enough holes to fit a washer through.
This did not work freehand, but luckily enough I found some bolts that had the perfect length to just reach through the box section.
I'm using scrap from the desks I built (steel was used as support for a 2.7m span) and I remembered how much of a pain it was to drill about 60 holes in them with HSS and got myself a cobalt drill instead.
Cobalt drills are awesome and I will just use them in the future.
On Friday I took a longer lunchbreak and used the good weather to cut the flat that will form the support plates for the wooden bottoms in the layers that need them, and the ends for the axle:
In the evening I marked up the positions for the holes:
Which I then drilled in the shed. Judging by the heavy package I had to carry up the stairs the other week I am getting a pillar drill for my birthday, but for now we'll have to do it by hand (with my grandfather's drill!)
This worked fine with my m4.5. It got a little trickier when moving up to the M10.
Sometimes one has to make do...
The cobalt is great, but at that speed it does bite down if you're not careful and my holes were... less than spot on.
Given the fact the axle is stationary and I'm not too concerned about the handling of my cart I'm no too concerned
So the Friday went pretty decently.
Saturday 13/02/2021
Saturday was quite windy, so I made a little makeshift workspace with wind shielding and welded in-between gusts of wind.
Figured out the settings for the 3mm plate, and tacked everything up.
Welded everything on. Still a little erratic but I'll keep on practicing. Tried welding some of the inside corners as well, but because of the flat meeting the box section on the rounded corner I have sort of a gap between them, and everything is very tricky to reach. Rather than just spamming molten metal al over the place I figured the welds I did on the bottom would easily support the loads it'll have to bear.
Then put on the end caps for the axle. The weld looks pretty I think. It looks a bit cold because of how raised it is, but I could see it melt into the material and it definitely penetrated well. Maybe my wirespeed was a bit high for this join as I used the same speed I did for the flats against the bottom of the box section (2 to 3mm lap joint at 5.5/10 wirespeed)
I then cut the triangles that will be used in the inside corners of the upright, and wanted to use my newly acquired marking fluid to mark out the radius for grinding off. It came with sort of a felt-tip pen cap that didn't work very well.
Being a bit thick I decided to squeeze the bottle...
Lets just say I was grateful for a few things.
Grateful I was gearing safety goggle, because I reckon that stuff is not pleasant in the eyes.
Grateful I did this in the shed, not on the dining table (girlfriend would have killed me)
And grateful said girlfriend had nail-polish remover so I no longer look like a smurf...
And with that I was done for the Saturday.
Sunday was a bit of a loss. All rain and wind. I did manage to drill the holes that will be sued to attach the welder to the top section.
Planned to use my HSS hole-saw (only used for plastic so far) to make large enough holes to fit a washer through.
This did not work freehand, but luckily enough I found some bolts that had the perfect length to just reach through the box section.
I'm using scrap from the desks I built (steel was used as support for a 2.7m span) and I remembered how much of a pain it was to drill about 60 holes in them with HSS and got myself a cobalt drill instead.
Cobalt drills are awesome and I will just use them in the future.
slim_boy_fat
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Helder
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- Swindon, Wiltshire, UK
I've been spending lunch breaks outside grinding my flanges close to the line. And then filing them into shape in the evenings. Filing is nice, very relaxing.
3 more to finish tonight.
Also marked out the sides for my revised handle, will be using a piece of an old broken broom.
And cut two pieces to be bent into hooks to hold the lead and ground cable.
I'll have to see how I'm going to bend the metal, as it's 3mm and I don't have any tools to do it with.
I was thinking of clamping it between and old sledgehammer head I found in the garden and a piece of scrap and try to bash it to 90 degrees with a mallet.
If that doesn't work I'll grind out a groove, bend and weld, we'll see.
3 more to finish tonight.
Also marked out the sides for my revised handle, will be using a piece of an old broken broom.
And cut two pieces to be bent into hooks to hold the lead and ground cable.
I'll have to see how I'm going to bend the metal, as it's 3mm and I don't have any tools to do it with.
I was thinking of clamping it between and old sledgehammer head I found in the garden and a piece of scrap and try to bash it to 90 degrees with a mallet.
If that doesn't work I'll grind out a groove, bend and weld, we'll see.
slim_boy_fat
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You can get Counselling for that....
[Sorry....
]You need a linisher in your life, it'd make short work of that.
For the bending metal, heat in the form of oxy/propane is your friend. 
Helder
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- Swindon, Wiltshire, UK
I'll put those on my ever growing list of toys I want. For now I'm afraid I'll have to make do.You can get Counselling for that....
You need a linisher in your life, it'd make short work of that.
First projects are building an awning/veranda. Insulating and damp-proofing the shed. Building some proper workbenches, and then putting a small mill and lathe on them.
A linisher seems a good first project using those machines though!
slim_boy_fat
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Helder
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And some more work during my lunch break while its dry.
Finished the brackets that'll hold the handle on the front:
And laid out some parts to mark off which parts to brush clean for welding (and have a look!):
Well chuffed. It's going to be an absolute tank
Finished the brackets that'll hold the handle on the front:
And laid out some parts to mark off which parts to brush clean for welding (and have a look!):
Well chuffed. It's going to be an absolute tank
Helder
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- Swindon, Wiltshire, UK
Another bit of work done during an extended lunch break (hurrah for overtime)
Used the next layer to square everything up (which took me ages to get right)
Feel like the weld are getting neater.
And the result.
This one's the alien, I'll have to do the predator next
As a side note, because my cuts are less than perfect with the angle grinder I sometimes have a bit of a gap here and there that I find hard to bridge.
Now the right way to solve that is taking the grinder to it, and getting everything neater to fit better, or even cutting a new part.
What I've been doing (since it's not that structural and I can't be bothered is just trying to bridge it, and doing a second pass where I can't make it.
Are there any better ways to bodge stuff like this, perhaps put a little piece of filler metal in there?
And just how bad is this solution if I give the welds a good proper brushing inbetween to get the crud off?
Used the next layer to square everything up (which took me ages to get right)
Feel like the weld are getting neater.
And the result.
This one's the alien, I'll have to do the predator next
As a side note, because my cuts are less than perfect with the angle grinder I sometimes have a bit of a gap here and there that I find hard to bridge.
Now the right way to solve that is taking the grinder to it, and getting everything neater to fit better, or even cutting a new part.
What I've been doing (since it's not that structural and I can't be bothered is just trying to bridge it, and doing a second pass where I can't make it.
Are there any better ways to bodge stuff like this, perhaps put a little piece of filler metal in there?
And just how bad is this solution if I give the welds a good proper brushing inbetween to get the crud off?
Helder
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- 37
- Location
- Swindon, Wiltshire, UK
Saturday 20/02/2021
Had an absolutely brilliant weekend. Got the last layer on Saturday morning. Then welded on the flanges, and tabs for the handle with the welder inside the shed inbetween bouts of rain.
Took a bit of trial and error to get proper penetration on the flanges, but I got it decent at the end.
At a little over 13st/84kg I'd say that's plenty strong.
Put the welder on to see how it sat and try out where to put the hooks for the leads, and welded them on last thing on Saturday.
I was unable to bend them cold at 3mm so I ground a slit in, and bent and welded them after attaching them to the frame.
Sunday 21/02/2021
I found some very strange metal in the shed. It doesn't weld, but it's easy to work with and smells nice. Did that inside whilst it rained outside.
Then when it dried up outside the arduous task of cleaning everything up began. Washed everything with soapy water with detergent (won't do that again, made everything rust pretty much instantly.
The took a grinder, flap disk and wire brush to it until it was all clean (well there was a little bit of surface rust in the nooks and crannies that I couldn't get to. Hope that'll be ok, but we'll see).
A grinder and paint make the welder I aint...
One day we'll have beads so nice I'll want them on display. Until that time...
And then finally I gave her a thorough clean with break cleaner and mixed up the 2k epoxy primer.
Well pleased with that. It was a tremendous amount of work but man, working with metal is NICE. It's so nice and solid.
Just have to finish up with a final coat of paint, and then stain and slap the wood on, and cut the padding for the gas bottle to size.
To be continued...
Had an absolutely brilliant weekend. Got the last layer on Saturday morning. Then welded on the flanges, and tabs for the handle with the welder inside the shed inbetween bouts of rain.
Took a bit of trial and error to get proper penetration on the flanges, but I got it decent at the end.
At a little over 13st/84kg I'd say that's plenty strong.
Put the welder on to see how it sat and try out where to put the hooks for the leads, and welded them on last thing on Saturday.
I was unable to bend them cold at 3mm so I ground a slit in, and bent and welded them after attaching them to the frame.
Sunday 21/02/2021
I found some very strange metal in the shed. It doesn't weld, but it's easy to work with and smells nice. Did that inside whilst it rained outside.
Then when it dried up outside the arduous task of cleaning everything up began. Washed everything with soapy water with detergent (won't do that again, made everything rust pretty much instantly.
The took a grinder, flap disk and wire brush to it until it was all clean (well there was a little bit of surface rust in the nooks and crannies that I couldn't get to. Hope that'll be ok, but we'll see).
A grinder and paint make the welder I aint...
One day we'll have beads so nice I'll want them on display. Until that time...
And then finally I gave her a thorough clean with break cleaner and mixed up the 2k epoxy primer.
Well pleased with that. It was a tremendous amount of work but man, working with metal is NICE. It's so nice and solid.
Just have to finish up with a final coat of paint, and then stain and slap the wood on, and cut the padding for the gas bottle to size.
To be continued...
Helder
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- 37
- Location
- Swindon, Wiltshire, UK
Oh dear. And I was thinking they felt alright. We'll see how they hold up.
Helder
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- Messages
- 37
- Location
- Swindon, Wiltshire, UK
With not much left to do I put on the last coat of paint on Friday evening and put it all together the following morning.
I'm very very pleased with the way it all turned out.
The finish on the wood is Osmo top oil acacia.
Works very nicely with the matt black I think.
The gas bottle is secured with a cut up knee matt and nice and secure without any banging around.
I will have to build a little ramp up to my shed though because it is HEAVY.
I'm very very pleased with the way it all turned out.
The finish on the wood is Osmo top oil acacia.
Works very nicely with the matt black I think.
The gas bottle is secured with a cut up knee matt and nice and secure without any banging around.
I will have to build a little ramp up to my shed though because it is HEAVY.
selectedgrub
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Wow,
Get some decent wheels on it and you'll be able to ride it down the M5
Get some decent wheels on it and you'll be able to ride it down the M5
