Grease Gun Hydroforms Custom Motorcycle Parts

Never underestimate the power of an incompressible fluid at high pressure. Properly constrained and with a full understanding of the forces involved, hydraulic pressure can be harnessed to do some interesting things in the home shop, like hydroforming stainless steel into custom motorcycle parts.

From the look of [Clarence Elias]’s video below, it seems like he has a 100% custom motorcycle build going on in his shop. That means making every part, including the reflectors for the lights. While he certainly could have used a traditional approach, like beating sheet stainless with a planishing hammer or subjecting it to the dreaded English wheel, [Clarence] built a simple yet sturdy hydroforming die for the job. A thick steel ring clamps the sheet stainless to a basal platen with an inlet from the forming fluid, which is ordinary grease. [Clarence] goes through the math and the numbers are impressive — a 1,500-psi grease gun can be mighty persuasive under such circumstances. The result is a perfectly formed dish with no tool marks, in need of only a little polishing to be put into service.

Whether by a pressure washer, a puff of air, or 20-tons of pressure on a rubber pad, hydroforming is a great method to master for making custom parts.

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Beautiful Rocketeer Jetpack Replica Boasts Impressive Metalwork

Fans of the Rocketeer comic book and movie franchise will be familiar with its hero’s 1930s-styled rocket backpack.  It’s an intricate construction of complex streamlined curves, that has inspired many recreations over the years.

Most Rocketeer jetpacks are made from plastic, foam, and other lightweight materials that will be familiar to cosplayers and costumers. But [David Guyton]’s one is different, he’s made it from sheet steel.

The attraction in his video is not so much the finished pack, though that is an impressive build. Instead it’s the workmanship, nay, the craftsmanship, as he documents every stage of the metalwork involved. The panel beating tools of a sheet metalworker’s trade are surprisingly simple, and it’s tempting to think as you watch: “I could do that!”. But behind the short video clips and apparent speed of the build lies many hours of painstaking work and a huge amount of skill. Some of us will have tried this kind of sheet work, few of us will have taken it to this level.

The video is below the break, it takes us through the constituent parts of the build, including at the end some of the engine details which are cast in resin. Watch it with a sense of awe!

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Hacked Car Axle Yields Custom 90° Gearbox

Need a sturdy angle gearbox to handle power transmission for your next big project? Why not harvest a rear axle from a car and make one yourself?

When you think about it, the axle of a rear-wheel drive vehicle is really just a couple of 90° gearboxes linked together internally, and a pretty sturdy assembly that’s readily available for free or on the cheap. [Donn DIY]’s need for a gearbox to run a mower lead him to a boneyard for the raw material. The video below shows some truly impressive work with that indispensable tool of hardware hackers, the angle grinder. Not only does he amputate one of the half axles with it, he actually creates almost perfect splines on the remaining shortened shaft. Such work is usually done on a milling machine with a dividing head and an end mill, but [DonnDIY]’s junkyard approach worked great. Just goes to show how much you can accomplish with what you’ve got when you have no choice.

We’re surprised to not see any of [DonnDIY]’s projects featured here before, as he seems to have quite a body of hacks built up. We hope to feature some more of his stuff soon, but in the meantime, you can always check out some of the perils and pitfalls of automotive differentials.

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Chess Set From Car Parts

Chess has been around for an awfully long time, automobiles less so. However, there’s no reason the two can’t be combined, like in this chess set fashioned from automotive components.

The project was made as a gift, and is the sort of thing that’s quite accessible for an interested maker to attempt at home. Parts used to build the set include valves, valve springs, spark plugs, castellated nuts and pipe fittings. As the parts don’t actually need to be in good working condition, a haul like this could likely easily be had for less than $50 from the local pull-it-yourself wrecking yard — or free if you know a mechanic with some expired engines lying around.

The metalworking side of things involves trimming down and welding together the parts, before polishing them up and applying a coat of paint to create the white and black, or in this case, gold and black pieces.

Overall, it’s a fun weekend project that could be tackled in any number of ways depending on your creativity and taste. For a different take, check out this 3D laser cut chess set.

DIY Barrel Rifling with 3D Printed Help

[Jeff Rodriguez] has been busy testing a feasible DIY method for rifling a barrel and has found some success using salt water, a power supply, wire, and 3D printed parts to create the grooves of rifling without the need for any moving parts or cutting tools. Salt water flows between the barrel’s inside surface and a 3D-printed piece that holds wires in a precise pattern. A current flows between the barrel and the wires (which do not actually touch the inside of the barrel) and material is eroded away as a result. 10-15 minutes later there are some promising looking grooves in the test piece thanks to his DIY process.

Rifled barrels have been common since at least the 19th century (although it was certainly an intensive process) and it still remains a job best left to industrial settings; anyone who needs a barrel today normally just purchases a rifled barrel blank from a manufacturer. No one makes their own unless they want to for some reason, but that’s exactly where [Jeff] is coming from. The process looks messy, but [Jeff] has had a lot of space to experiment with a variety of different methods to get different results.

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DIY Roll Bender Keeps it Simple and Sturdy

If you’ve ever tried to bend a metal pipe or bar over your knee, you’ll know that even lightweight stock requires quite a bit of force. And the force needs to be properly directed, lest the smooth bend you seek become a kink or a crease. When your hands and knees no longer fill the bill, try [MakeItExtreme]’s sturdy and simple roll bender.

As we watched the video below, we had a little déjà vu — hadn’t the [MakeItExtreme] crew built a roll bender for their shop before? Turns out they had, but in reviewing that video, we can see why they gave it a second shot. This build is a model of simplicity compared to the previous. With a frame fabricated from just a few pieces of steel I-beam, this version is far more approachable than its big brother and just about as capable. The three forming rollers ride in stout pillow blocks and can be repositioned for different bending radii. A 2-ton hydraulic bottle jack provides the force needed to direct the stock through the rollers, which are manually powered. In a nice touch, the incomplete tool was used to create the rim of the large-diameter handwheel for the drive roller.

The tools keep piling up at [MakeItExtreme]’s open air workshop — we even get a glimpse of their heavy-lift electromagnet that we recently featured. As always, we love the fit and finish on these builds, and watching the time-lapse videos is like a condensed class in metalworking.

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New Lathe Day is Best Day

As [Quinn Dunki] rightly points out, modern industrial civilization was probably conceived on the bed of a lathe. Turning is an essential step in building every machine tool, including lathes, and [Quinn] decided it was time to invite one into her shop. But she discovered a dearth of information to guide the lathe newbie through that first purchase, and thus was born the first installment in her series on choosing and using a new lathe.

As for the specifics of the purchase, [Quinn]’s article goes into some depth on the “old US iron” versus “new Asian manufacture” conundrum. Most of us would love an old South Bend or Cincinnati lathe, but it may raise practical questions about space planning, electrical requirements, and how much work is needed to get the old timer working again. In the end, [Quinn] took the path of least resistance and ordered a new lathe of Chinese heritage. She goes into some detail as to what led to that decision, which should help other first-timers too, and provides a complete account of everything from uncrating to first chips.

Nothing beats the advice of a grizzled vet, but there’s a lot to be learned from someone who’s only a few steps ahead of her intended audience. And once she’s got the lathe squared away, we trust she’ll find our tips for buying a mill helpful getting that next big shipment delivered.

“All the best things in life arrive on a pallet.” Have truer words ever been spoken? Sure, when the UPS truck pulls up with your latest Amazon or eBay treasure, it can be exciting. But a lift-gate truck rolling up to the curb? That’s a good day.