In this project I used various scrap metal parts I had in the shop to make a simple jig for making spheres on the lathe. I have made a similar jig out of wood in the past. But by using metal I was able to make the tool more simple, more efficient and less bulky.
I begun by making the base. I cut the pieces with the angle grinder and welded them in place. I then drilled the hole on my drill press and cut some threads to keep the piece in place. But I made a mistake here and I had to cut the piece in half.
For the arm I used a couple of corner pieces as support. I also welded nuts in place so I could use their threads.
To make the cutting edge, I used the steel from a cheap old turning tool. I grinded the bevels on the grinder. My grinder is really fast so I dipped the tool in water pretty often to cool it down.
I then grinded a pocket and welded the cutter in place.
After doing some tests, I decided to weld the nut from the pivot point. And I also added a large nail under the cutting edge as support. I wanted this to be removable so I could sharpen the tip easier on the grinder.
I then used my carbide burrs on the rotary tool to clean my welds a little bit. A wire brush bit is also useful to clean up before painting.
I then added a coat of primer and then spray painted orange.
Before you use the tool you have to set it up a little bit. The cutter should be at the same height of the centre of the lathe. And the pivot point should be under the centre of your sphere.
And my sphere making jig was ready to go. But that was it, see you soon with a new project video.
Disclosure: Some of the links below are affiliate links, meaning, that at no cost to you, I get a small commission if you click through and make a purchase.
In this video I make a basketball hoop out of reebar, 18mm plywood, some metal parts and nylon strings. This project combines metalworking and woodworking and it was a good opportunity for me to practice my stick welding skills.
First of all I used a scrap melamine piece to make a jig so I could bend the reebar close to a circle. I cut it out on the bandsaw and I divided it into 12 parts using my dividers. I used my jigsaw to cut some slots for the the clamps and I also made 4 pieces to help keep the clamps in place.
I then bended the reebar and clamped it in place. I found that using heat with a propane torch really helped. To finish the circle I welded morereebar on both ends to get more leaver power. Finally I welded the circle’s ends together and cut off the excess with the grinder. It really helps If you have someone to help you do this but I was alone in the shop. Anyway it was not super easy but it worked.
Then I welded the circle on a metal corner. I added more reebar in the areas I had more gaps. I used 2mm sticks and my welder was mainly set around 70amps.
Once I finished the hoop I cleaned it up with the grinder.
Then I used the grinder to cut grooves on the circle. On there I tack welded small metal hooks. These act as net holders. I smoothed everything out with the sanding flap disc on the grinder.
I primed and painted the circle.
I then drilled the holes for the nuts and bolts on the plywood. I cut the bolts flush with the grinder. I also used the grinder to chamfer the edges of the bolts.
I used a paint can a s guide to create round overs on the edges of the wood. I then cut them out on the bandsaw and used the sander to remove the saw marks.
I used the router with a round over bit to smooth the edges of the plywood.
I then nailed in place two spacers. I secured them in place with screws.
I masked the board with tape and then painted it black. I finished it with water based clear satin varnish.
To hang the hoop on the wall I bended two hooks on my vise and then screwed them in place. In future I will just screw the hoop on the wall.
Finally I made the net using two colours of 4.8mm nylon cord. This was pretty simple as you can see in the video.
My hoop came out great and it is ideal for small basket balls. But that was it. See you soon with a new project video.
Disclosure: Some of the links below are affiliate links, meaning, that at no cost to you, I get a small commission if you click through and make a purchase.
In this video I make a rotary tool holder out of scrap metal I had in the shop. This is really useful when you use your rotary tool with it's flexible arm accessory.
I begun by making the clamp of my holder. I first cut my pieces to size with the grinder. I used a magnetic corner to hold the pieces together. Then I tack welded to avoid the warping of the metal. After that I finished the seams.
I used several drill bits to open up a hole. Then I welded a nut in place. I then welded a nut on a washer to create the clamp’s moving end. To turn the clamps threaded rod I welded a nail in place.
I then cleaned all the pieces with the grinder. Then I fine tuned them with a sanding flap disc and a wire brush.
I drilled a hole on the clamps end and welded a nail in place. This acted as a locking pin.
To adjust the height of my holder I drilled the holes needed. I made a locking pin by welding a nail and a washer together.
I then used the grinder to create a v groove on the metal bar. I welded a threaded rod in place.
I applied a coat of metal primer to everything and then I finished with a couple of coats of silver spray paint.
To hold the rotary tool in place I just used a couple of washers and nuts.
I am really happy with this project. It’s much more robust that the holders you usually buy.
At this point I want to thank mr Stelios Fotakopoylos because he made a similar thing which inspired me to make mine. You can watch his video here.
But that was it see you soon with a new project video.
Disclosure: Some of the links below are affiliate links, meaning, that at no cost to you, I get a small commission if you click through and make a purchase.
I wanted to make a metallic guitar and I came up with a three string concept guitar.
First of all I made a cardboard template of my guitar's body. I then transferred the template on a piece of melamine.
I used the bandsaw to cut the shape out. Using a forstner bit on my drill, I opened up holes on the melamine. Those will help me for clamping later on. I cleaned the bandsaw marks on my belt sander.
I used a piece of cord to measure the perimeter of my piece. I then transferred the measurement on a piece of steel. I cut the metal to length with the angle grinder. I drilled a hole in the center of the piece. I used a drop of oil to prevent my drill bit from overheating.
I predrilled a pilot hole on the melamine and screwed the metal piece on the melamine.
I used the blow torch to heat the metal and then bended in place.I then added a clamp. This technique worked out OK but I still had to do a lot of fine tunings to get the shape I wanted.
I measured the length of the fretboard. I then cut the fretboard to size with the angle grinder. I used an air powered rotary tool to clean the burrs on the metal.
I then stick welded the fretboard to the body. I used the grinder with a sanding disc to clean up the welds.
To make the headstock I cut another piece of steel. To bend it to shape easier, I used the grinder to create grooves at the points I wanted to bend it. But this technique did not work out that well. I should have welded all the parts individually. Anyway, I moved on and welded the headstock to the finger board. I then forced the pieces in place with the vise and welded them together.
The headstock looked a little bulky, so I trimmed it a little using the grinder to make it nicer.
I drilled the holes for the tuning pegs, Im used a step drill bit for this job.
To support the bridge and the pickup of the instrument I welded two metal pieces perpendicular to the body. I then used the grinder to trim the excess pieces flush.
I temporarily clamped the pickup in place and used a drill to mark the holes I needed.
I cut two pieces of angled stock to act as bridge and nut. I then welded them in place.
The scale of my instrument from nut to bridge is 60cm.
I drilled the holes for the screws which hold the tuning pegs in place.
I drilled the hole for the output jack.
I used an online fret calculator to find the positions of the frets. I marked the fret positions and used the angle grinder to create the fret marks. Since this instrument will be played with a slide the frets are actually guidelines to help me keep my intonation.
I then drilled holes for the 3rd, 5th, 7th, 9th and 12th fret. I did the same on the side of the finger board.
I gave everything a final sanding with the grinder.
I shaped the bridge and nut to an edge to avoid string buzzing.
Using mineral spirit I wiped off the dust. I wanted to keep the rough look of the guitar, so I finished it with a couple of clear coats to keep it rust free.
I then installed the tuning pegs. Using my rotary tool, I trimmed the excess screws.
I installed the pickups and the output jack.
I used the wire stripper on the pickup's cables. I soldered the ends of the cables and the jack. Now that everything was pre-coated with solder it was much easier to join them.
I connected the guitar on the amp to check that the pickup works. I hit the pickup with a metal object. If that sound goes through the amp without funny noises, everything works fine.
I then added the middle string and marked it's place on the nut and bridge. With a square file I opened up grooves for the string to rest. I repeated the process for the other two strings.
I lifted the pickup closer to the strings to get more volume from it.
I tuned the guitar in D A D . This way you have a D5 chord when you hit all the strings open.
At this point my instrument was ready, and I am really happy with the way it came out! :)
This is my first stick welding project. It is an insect sculpture I made out of scrap metal pieces. It was really fun to make and I learned a lotthrough the process.
The whole thing is made out of scrap metal. The grasshopper idea, was inspired by the shape of an old tool I had in the shop.
First of all I cleaned the tool a little bit, using a wire brush on my drill.
Then I welded the moving parts of the tool, in the position I wanted.
I used a hammer to remove the borax and check how my welds came out.
I then welded two nuts to act as eyes.
I made the front four legs of the grasshopper using large nails. I bended them in shape using a hammer on my vise.
To keep the nails in place for the welding, I used my soldering station.
I made the back legs out of a thick metal rod. I cut them in place with the angle grinder, then I heated them with a blow torch and finally used a metal tube as a leaver, to bend them in shape. At the end of each leg I soldered a washer to act as sole.
I then designed the shape of the wing on a 3mm metal sheet. I used my grinder to cut the shape out. For the curved parts I created relief cuts, to help me with the cutting. I also used the grinder to clean up the burs. After that was done, I used the first wing as a template to make the other.
I then welded the wings in place.
I sanded the welds using a sanding disc, on my grinder. To reach a few hard spots, I used my rotary tool with a cone stone grinding bit. But the metal was too hard and that did not work that well!
At this point the sculpture was ready. I finished with two light coats of gold spray paint.
I really enjoyed this project. My welds came out awful, but I really enjoyed welding. I also learned a ton of stuff!
