Metalwork and Fabrication

[demoj]

Afternoon all!
I don't know if there is a specific fabrication thread (I did not see anything dedicated) I figured there should be a space for sharing fabrication techniques and advice. A new tool addition inspired me to share...

You know; genius, stupidity, mental illness, injuries, experiments, fire, trial and error all regarding metal and other DIY adventures.

I wanted to start by sharing my new favorite tool. My Makita cold saw...
Amazing- not cheap but expedites fabrication impressively through speed, accuracy and no need for cleanup. It's a $400 or so tool but worth every penny.

It's fast, clean, cool, accurate cuts with ZERO clean-up. (well near zero if you have knucklehead students jacking things up) It sank through Lurches Stainless Steel stock like BUTTA!
Check out my sexy 45's... They came off of the saw that clean and I slappedem in the vice. (building a Kayak rack for Stace and I)

It is far quieter far more accurate, not stinky/no inhalation hazard, less messy than the barbaric carborundum blade chop saw.

YUCKY!- sending mine to surplus.

I think I already shared my Moto Scout Rack and Luggage Rack builds with the group but if there is interest in budget steel bending I will post my strategies!

Lurch do we have any images of the ShopBot cutting your templates?

 

[lurch]

You know it!

 

[demoj]

Here is the reinforced trailer hitch mount I made for the kayaks. 2x2 16ga wall square tube with a 16ga center strip for strength at the tongue. We’ll see how well it works. Not done with the yak mounting yet.

 

[Mauser]

Cool. Those saws are great. The only problem is the tiny pieces that it throws off are super sharp little splinters that will get stuck in the bottom of your shoes then easily transfer to carpet.

I am interested in your bending methods.

Putting the strip down the center of the 2x2 tube is a cool idea too. I'm lazy though and probably would have welded 2 pieces of 1x2 together.

That shopbot thing is neat. Can you use a plasma cutter instead of the router?

 

[demoj]

I have not had any issues with the chips- other than they are BLAZING hot- all heat from the cut is transferred to them. To keep them contained the instructions say to complete your cut but hold the saw down until it stops, they mostly all go into the collection tray.

Shop bot only runs a router, but can do aluminum- not tried it yet though.

My bending buddy. The B.A. Baracus Wilton vice.

I weld up dies, with whatever I need on 16ga sleeves that sit in the vice.

I mark a register line on the center of the bending die tube. That corresponds with the measurements and bend lines on the stock.

The whole kit gets clamped into the vice and then I get out the shop multi tools.

 

[Mauser]

Man I'd love to have that vice.

This is my most used and one of my favorite fab tools.

Just the table top is 928 pounds. It is nice and flat with nice sharp square edges. I found loaded on a trailer destined for scrap.

 

[demoj]

Yeah, the vice is definitely the heart of the shop, our fab table is "pretty nice" with the exception of being abused by students and... super befuddling as to why this is- the surface is out of square?! I wrecked a ton of projects because of that assumption.

Couple other dies.

 

[Dumpolina]

@demoj where did you get the saw and what model is it? How is cut quality now that you have some use on the blade?

 

[alia176]

Is there a way to nicely bend alum square tubing w/o kinking? Say, 3/4 x 3/4 x 1/8 or 1 x 1 x 1/8. I need to build a full length rack for the Kamparoo.....some day. I just want the corners to be rounded vs square, simply for elegant's sake.

 

[demoj]

The saw is a Makita LC1230- not many cuts have been performed but it was mistreated by a student. I may need to adjust it, the cuts are super clean but after the *mishap* it leaves just a tiny bit of knock off.

As far as bending aluminum tubing nicely without kinking.... OF COURSE there is.... how much money do you have? not much money?? how much time do you have??

Lets face it Ali..... everyone knows your tube is totally kinked- I wouldn't bother trying to hide it.

The trick for bending square tubing- have a die for the inside bend that has a mound profile on the die edge.
What dimension for tube? 1x1"?
I have also used relief cuts and welded them back together-this can be BUTT ugly if you are not adept at finish work.
I have been shopping for a tube bender for our shop.. not sure if it is in the near future or not considering the layers of dead machines that are accumulating.

 

[lurch]

Anyone got dimple dies? I’m looking to use 0.75” size in an up coming project...

 

[Mauser]

Anyone got dimple dies? I’m looking to use 0.75” size in an up coming project...

I do. When do you need it?

 

[lurch]

Maybe in the early summer time frame...no rush and mainly seeing if I needed to budget for them at this point. I still have to get my drawings made and pieces cut. Oh and get through the semester

 

[Tank5]

Anyone have a mag drill they would loan me?

Edit: I got it taken care of.

 

[lurch]

I do. When do you need it?

@Mauser Any chance of having a 1.25" dimple die?
I'm designing my sliders now and I think 1.25"would be better....

 

[Mauser]

@Mauser Any chance of having a 1.25" dimple die?
I'm designing my sliders now and I think 1.25"would be better....
View attachment 2343688

Biggest I have is 1"

 

[CenTXFJ60]

I have not had any issues with the chips- other than they are BLAZING hot- all heat from the cut is transferred to them. To keep them contained the instructions say to complete your cut but hold the saw down until it stops, they mostly all go into the collection tray.

Shop bot only runs a router, but can do aluminum- not tried it yet though.

View attachment 2027679My bending buddy. The B.A. Baracus Wilton vice.
View attachment 2027682I weld up dies, with whatever I need on 16ga sleeves that sit in the vice.
View attachment 2027686I mark a register line on the center of the bending die tube. That corresponds with the measurements and bend lines on the stock.
View attachment 2027697The whole kit gets clamped into the vice and then I get out the shop multi tools.

View attachment 2027700

my vice is very similar to this one. Second best gift from my father in law right behind getting his 2240 15 years ago . That Vice has built swing out bumpers and a whole mess of other things over the years

 

[Mauser]

@Mauser Any chance of having a 1.25" dimple die?
I'm designing my sliders now and I think 1.25"would be better....
View attachment 2343688

You nerds and your computer programs.

 

[alia176]

You nerds and your computer programs.

Electrons are cheap vs cutting and rewelding

 

[thegadgetguy]

Ain’t that the truth