17-11-2012, 11:13 AM
Hi,
I'm pleased to learn of your steady progress Ollie and am following your story with interest rather than amusement because such stories/projects encourage others to have a go.
I too used to have to mechanically fasten items together; nuts & bolts; rivets; self tappers etc. but as you rightly say it is a very slow process as everything needs taking apart so many times and this can ruin concentration. Files and hacksaw are demanding on arms but good exercise and with practice very accurate results can be achieved; I was taught as an apprentice to file to a thou and this has never left me; I'm so used to using the hacksaw that I reach for this when cutting timber to length.
Its a good idea to use an existing grinder if a spare motor is unavailable but please be aware that the grinder speed needs to be taken into consideration; a number of manufacturers supply belt sander/grinder machines which might give you more ideas to work with (or more frustrations).
http://www.toolsoutlet.com/0305-0063.html
The “u” section metal you refer to Ollie is “channel” this is very common and used by industry in large quantities; offcuts of this are always handy to have in stock as it comes in handy.
As I progressed I tended to use less nuts and bolts and started to drill and tap but then taps need to be bought. Drilling large holes with an electric drill is very hard work and if the drill doesn't have variable speed then the larger bits run hot and soon become blunt; it's always fun when breaking through using a big bit; I remember only too well the time I was standing on a 1” thick steel plate whilst drilling a large hole and as I was wearing hob nailed boots when the bit grabbed as it broke through I spun around. You say you are new to metalwork Ollie so if you haven't already worked it out if you want to drill a biggish hole in metal using an electic drill always drill a small diameter pilot hole first say 1/8” diameter; it makes life a lot easier.
Welding is extremely useful Ollie but even this comes with problems; An arc (stick) welder can be bought quite cheaply and an industrial sized box of electrodes works out much cheaper than buying small packs and a box lasts for ages. Welding takes practice and a novice ends up suffering from welding flash and panicking when the rod sticks; with practice and no longer blinded it doesn't take long to start laying down a decent weld. Unlike using nuts and bolts though once two pieces of metal are welded they sure take some separating so its a case of planning and getting it right first time. When I play around with metal I wouldn't be without my welder. One power tool I dislike with a passion is my small angle grinder; it's a very good tool but I always dislike using it. The angle grinder is very useful for fettling sharp edges but it is noisy and showers hot sparks everywhere so plenty of safety kit needs to be worn; goggles are a must; ear defenders and gloves. Welding is also hazardous due to heat and sparks so great care is needed not to weld near combustible materials or liquids. Welded metal remains very hot for ages and after picking a few hot items up wearing welding gloves becomes natural. The pieces of metal to be welded must also be brought into close proximity; if heavy enough they can simply be butted together before tack welding; otherwise clamping is necessary. Always tack weld first then check and double check all is well before completing the weld A small engineers square is worth its weight in gold for checking pieces being welded at right angles.
As with anyone used to doing a job for many years it is so easy to forget just how difficult simple jobs can be to a novice; I do many jobs without even having to think about how to proceed as I've done the job many times but with every new or unfamiliar task I'm brought straight back to the novice stage having to learn as I proceed but of course with a lot of back up experience to rely on unlike a novice. Sorry to preach but many novices are afraid to ask the basic questions in case they appear to be silly but I work on the principle if I want to know I ask and I don't care how silly or even stupid the question appears to be because I'm sure many will have wanted to ask the same question. If you need information Ollie please send me an email or PM and I'll be leased to help if I can.
I'm sure as you gain more experience Ollie you will enjoy working with lumps of metal; it's a whole new world with lots to learn. Even after 50 years I still get a buzz out of designing something and making it come to life in metal; to see something I have made from lifeless pieces of metal come to life always gives me a great deal of satisfaction. Small projects lead to bigger more complicated projects; with each project more tools/kit are gathered and after a while machines suddenly become very appealing; power saws; grinders and lathes etc.; once you start dreaming about lathes then all is lost and there is no going back. A lot can be achieved using a hacksaw; hand files and an electric drill coupled with patience; once machines appear then oh boy what fun can be had.
Many videos are now available on “You tube” showing lots of projects and as we are allowed to join as many forums as we like I joined both woodworking and metalworking forums. You might be interest Ollie in another forum I'm a member of and before Mark keeps me in after school I hasten to add I'm not trying to poach members from this excellent forum.
http://www.practicalmachinist.com/
Practical Machinist is to metalwork as GF is to vintage radio.
I've been an active member of GF for quite a while and it's common knowledge that after ten years of restoring vintage radios I have now cleared out my electronics workshop to convert the workshop back to woodworking. I am however delighted that GF has this metalwork section as it allows me to keep boring you all whilst remaining an active forum member which I hope to continue.
I wish I had the time to read all the threads but can only “cherry pick” the ones which catch my eye although I do keep checking this section on a regular basis. Sorry guys if I don't reply to your threads but I simply don't have the time to play with vintage radio and my other hobbies at the same time.
I'm currently upgrading a Union Jubilee wood-turning lathe adding a 1.1Kw 3 phase motor powered through a new 2.2Kw VFD and for good measure I'm having headaches trying to graft on a clutch but hopefully if successful I'll add the full story at a later date.
Kind regards, Col.
I'm pleased to learn of your steady progress Ollie and am following your story with interest rather than amusement because such stories/projects encourage others to have a go.
I too used to have to mechanically fasten items together; nuts & bolts; rivets; self tappers etc. but as you rightly say it is a very slow process as everything needs taking apart so many times and this can ruin concentration. Files and hacksaw are demanding on arms but good exercise and with practice very accurate results can be achieved; I was taught as an apprentice to file to a thou and this has never left me; I'm so used to using the hacksaw that I reach for this when cutting timber to length.
Its a good idea to use an existing grinder if a spare motor is unavailable but please be aware that the grinder speed needs to be taken into consideration; a number of manufacturers supply belt sander/grinder machines which might give you more ideas to work with (or more frustrations).
http://www.toolsoutlet.com/0305-0063.html
The “u” section metal you refer to Ollie is “channel” this is very common and used by industry in large quantities; offcuts of this are always handy to have in stock as it comes in handy.
As I progressed I tended to use less nuts and bolts and started to drill and tap but then taps need to be bought. Drilling large holes with an electric drill is very hard work and if the drill doesn't have variable speed then the larger bits run hot and soon become blunt; it's always fun when breaking through using a big bit; I remember only too well the time I was standing on a 1” thick steel plate whilst drilling a large hole and as I was wearing hob nailed boots when the bit grabbed as it broke through I spun around. You say you are new to metalwork Ollie so if you haven't already worked it out if you want to drill a biggish hole in metal using an electic drill always drill a small diameter pilot hole first say 1/8” diameter; it makes life a lot easier.
Welding is extremely useful Ollie but even this comes with problems; An arc (stick) welder can be bought quite cheaply and an industrial sized box of electrodes works out much cheaper than buying small packs and a box lasts for ages. Welding takes practice and a novice ends up suffering from welding flash and panicking when the rod sticks; with practice and no longer blinded it doesn't take long to start laying down a decent weld. Unlike using nuts and bolts though once two pieces of metal are welded they sure take some separating so its a case of planning and getting it right first time. When I play around with metal I wouldn't be without my welder. One power tool I dislike with a passion is my small angle grinder; it's a very good tool but I always dislike using it. The angle grinder is very useful for fettling sharp edges but it is noisy and showers hot sparks everywhere so plenty of safety kit needs to be worn; goggles are a must; ear defenders and gloves. Welding is also hazardous due to heat and sparks so great care is needed not to weld near combustible materials or liquids. Welded metal remains very hot for ages and after picking a few hot items up wearing welding gloves becomes natural. The pieces of metal to be welded must also be brought into close proximity; if heavy enough they can simply be butted together before tack welding; otherwise clamping is necessary. Always tack weld first then check and double check all is well before completing the weld A small engineers square is worth its weight in gold for checking pieces being welded at right angles.
As with anyone used to doing a job for many years it is so easy to forget just how difficult simple jobs can be to a novice; I do many jobs without even having to think about how to proceed as I've done the job many times but with every new or unfamiliar task I'm brought straight back to the novice stage having to learn as I proceed but of course with a lot of back up experience to rely on unlike a novice. Sorry to preach but many novices are afraid to ask the basic questions in case they appear to be silly but I work on the principle if I want to know I ask and I don't care how silly or even stupid the question appears to be because I'm sure many will have wanted to ask the same question. If you need information Ollie please send me an email or PM and I'll be leased to help if I can.
I'm sure as you gain more experience Ollie you will enjoy working with lumps of metal; it's a whole new world with lots to learn. Even after 50 years I still get a buzz out of designing something and making it come to life in metal; to see something I have made from lifeless pieces of metal come to life always gives me a great deal of satisfaction. Small projects lead to bigger more complicated projects; with each project more tools/kit are gathered and after a while machines suddenly become very appealing; power saws; grinders and lathes etc.; once you start dreaming about lathes then all is lost and there is no going back. A lot can be achieved using a hacksaw; hand files and an electric drill coupled with patience; once machines appear then oh boy what fun can be had.
Many videos are now available on “You tube” showing lots of projects and as we are allowed to join as many forums as we like I joined both woodworking and metalworking forums. You might be interest Ollie in another forum I'm a member of and before Mark keeps me in after school I hasten to add I'm not trying to poach members from this excellent forum.
http://www.practicalmachinist.com/
Practical Machinist is to metalwork as GF is to vintage radio.
I've been an active member of GF for quite a while and it's common knowledge that after ten years of restoring vintage radios I have now cleared out my electronics workshop to convert the workshop back to woodworking. I am however delighted that GF has this metalwork section as it allows me to keep boring you all whilst remaining an active forum member which I hope to continue.
I wish I had the time to read all the threads but can only “cherry pick” the ones which catch my eye although I do keep checking this section on a regular basis. Sorry guys if I don't reply to your threads but I simply don't have the time to play with vintage radio and my other hobbies at the same time.
I'm currently upgrading a Union Jubilee wood-turning lathe adding a 1.1Kw 3 phase motor powered through a new 2.2Kw VFD and for good measure I'm having headaches trying to graft on a clutch but hopefully if successful I'll add the full story at a later date.
Kind regards, Col.
Happiness is a wreck of a cabinet to restore.
