The Art And Science Of Bending Sheet Metal

A motor mount. A sturdy enclosure. A 43.7° bracket. The average hack requires at least one angled metal part, and the best tool to make one is still the good ol’ press brake. Bending parts requires a few extra thoughts in the design and layout of the flat patterns, so if you want to know about bend allowances, bend deduction and how to bend accurate parts even without a press, read on.

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Building a Sheet Metal Pistol

Floating around the Internet are plans for a semi-automatic pistol constructed out of sheet metal. Like so many plans for 3D printed guns, it appears no one has actually built one of these pistols. It exists only as a technological construct, with diagrams you can photocopy, trace onto a few bits of metal, and presumably assemble into a gun. The only proof these parts can be turned into a gun-shaped object are a few random blog posts from two years ago showing a very ugly pistol spray painted matte black.

[Clinton Westwood] decided to take up the challenge of turning these plans into a real, working gun. He’s documented his efforts on YouTube and put a bunch of pictures up of the entire build process. The gun doesn’t work quite yet, but it almost does, and he’s doing this entirely in a garage shop, with tools anyone can pick up from Home Depot.

Most of the construction of this gun is simple enough – it’s just sheet metal, after all. The magazine was constructed by tracing the pattern onto a piece of metal, wrapping it around a mandrel, and welding it together. The side plates of the gun, again, were created with a jigsaw. Rifling the barrel – the thing that makes this gun both accurate and legal – required the construction of a few interesting tools. The rifling tool is just a piece of round bar that fits through the barrel. A small piece of a hacksaw blade was cut to fit inside this round bar, and the barrel was cut very slowly with a shop-built tool.

The finished result is something that looks like it came from the finest post-apocalyptic craftsman. A gun that looks cool is useless if it doesn’t work, and here the DIY pistol falls short. The spent casings don’t eject. It’s still a step up from the first build of this gun that was only rumored to fire blanks.

Recently, the world of gunsmithing has been inundated with 3D printed pistols that don’t work, and 3D printed guns that do work, but are somehow 200 years behind the state of the art. We’re happy to see some people are still building things with their hands, and hope [Clinton] can eventually get this gun to work.

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Gitaar van Schroot – The Scrap Metal Guitar

Sheet metal. Beer cans. Pieces of chain. Not items you’ll typically find on the BOM for a custom guitar. But nobody told [Maarten van Halderen] that, and so he threw them all together into a gitaar van schroot, or scrap guitar for the Dutch impaired (YouTube link).

The video shows the build process, starting with plasma cutting and welding sheet steel for the body. The neck is fabricated from rectangular steel tube, with nails serving as frets. Overall it looks like a Les Paul, except for the sink strainer basket mounted in the sound hole and the crushed beer and soda cans tacked to the body for decoration. The chains are a nice touch too. And this doesn’t appear to be [Maarten]’s first attempt at scrapyard lutherie  – toward the end of the video we see that the beer can axe joins a very steam-punk looking older brother. They’re both good-looking builds, and the video after the break proves they can sound pretty good too.

For a more classical take on the building of string instruments, check out this post on mandolins and violas. Or maybe you can just 3D print your next guitar?

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Hackaday Links: November 4, 2012

Wait, you’re using a Dremel to cut PCBs?

Cutting copper-clad board or – horrors – depanelizing PCBs is a pain if you don’t have the right tool. Over at Hub City Labs they’re using a small, cheap metal shear & break. Bonus: it can cut and bend sheet metal, so the Hub City folks can also make enclosures.

Color Codes? Yes, Color Codes.

[Joe] sent in a cool utility he whipped up called resisto.rs. Plug in a resistor value, and it’ll spit out the 4-band, 5-band, and surface mount labels for that resistor value. Pretty neat.

Parallel Ports

Parallel ports may be a dying breed, but that didn’t stop [Electroalek] from putting together a VU meter that connects to his LPT port. It’s an extremely simple design; just connect some LEDs and resistors to the pins of a parallel port, and you can easily control them via software on a computer. Playing around with an LPT port used to be common knowledge, so we’re glad to see [Electroalek]’s work here.

The power is out, but Radio Shack is still open

[Jason] is stuck in New Jersey without power and needed a way to charge his phone. He whipped up a cell phone charger using an RC car battery and an LM317 voltage regulator. It’s an easy circuit to piece together, and judging from [Jason]’s picture will hopefully keep his cell phone charged until the power comes back on.

Shooting 50 Nerf darts all at once

If [Rob]’s project log is to be believed, it looks like they’re having a lot of fun over in the Sparkfun warehouse. They decided to have a full-scale Nerf gun war for a summer intern’s last day. [Rob] came up with a DIY Nerf shotgun that shoots 50 darts across the room, just waiting to be found sometime in the next decade.

There’s a great video of [Rob] firing the single barrel (yeah, they made a trident-shaped one as well) gun at well prepared but unsuspecting coworkers. Be sure to check out the comments of this post to see Hackaday readers frothing at the mouth because PVC pipe isn’t a pressure vessel guys. You’ll all surely die.

DIY spot welder makes metalwork easy

At Hackaday, we’ve seen enclosures built out of just about every material. From wood, glass, epoxy resin, plastic, and even paper, all these different types of enclosures provide some interesting properties. Sometimes, though, you need an enclosure made out of metal and welding together steel cases isn’t exactly easy or cheap. [manekinen] came up with a really great solution to the problem of welding together sheet metal. It’s a very easy to build spot welder perfect for fabbing steel cases.

The core of the build is a transformer pulled from a Technics stereo amplifier. [manekinen] removed the stock secondary winding and rewound the transformer four turns of 35mm ² wire (about 2 AWG). This made the transformer put out 2.6 Volts a 1 kA – more than enough to weld 22 ga sheet.

For the control mechanism, [manekinen] put a limit switch on the electrode arm and wired that to a timer. A knob on the front of the welder allows him to vary the time the welder is on from 0 seconds to 4 seconds.

The results are fantastic – trying to rip apart a weld only results in the metal itself tearing; exactly what you want to see in a welder. It’s a great build made even more fantastic by the welder building its own enclosure.

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