metalworking

73 Articles

Scratch-Built Rolling Tool Cabinet Is A Metalworking Skill-Builder

March 12, 2021 by 14 Comments

Yes, rolling tool cabinets in every conceivable shape, size, arrangement of drawers, and even color are readily available commercially, and you probably shouldn’t build your own. But as [Bob] from “Making Stuff” points out, where’s the fun in that?

Still, we can think of plenty of reasons to make your own rolling tool cabinets from scratch. Aside from the obvious benefits of practicing your metalworking skills and putting your tools to good use, rolling your own means you can get exactly what you want. Almost every tool cabinet we’ve purchased has ended up being just a bit sub-optimal in some way — too wide for the available space, or perhaps with drawers a touch too shallow to fit that one oddball tool. Being able to create your own cabinet means you can hit the specs exactly, and as [Bob] shows, it’s not even that hard if you have the right tools.

The build starts on [Bob]’s CNC plasma cutter, a shop-built machine that’s seen several upgrades over the years. The plasma cutter makes quick work of cutting the drawer blanks from sheet steel, complete with slots to make forming the sheets into drawers easy. The frame of the cabinet is steel tubing, which is welded up and filled in with more sheet steel. Full-extension ball-bearing slides are added to the sides to support the drawers; we have to admit that welding what appears to be zinc-coated steel makes us nervous, but we assume [Bob] took precautions against the potential for toxic fumes.

The video below shows the whole build process and shows off the very sharp-looking final product. It also puts us very much in the mood to build our own plasma cutter.

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Machining A Honing Jig Will Keep Skills Sharp

March 1, 2021 by 9 Comments

[Amy Makes Stuff] has long used a pair of diamond honing blocks to freehand sharpen planes, chisels, and all the other dull things around the shop. Although this method works fairly well, the results are often inconsistent without some kind of jig to hold the blade securely as it’s being sharpened. These types of devices are abundant and cheap to buy, but as [Amy] says in the video after the break, then she doesn’t get to machine anything. Boy, do we know that feeling.

[Amy] was able to make this completely out of stuff she had lying around, starting with a block of scrap aluminium that eventually gets cut into the two halves of the jig. The video is full of tips and tricks and it’s really interesting to see [Amy]’s processes up close. Our favorite part has to be that grippy knob that expands and contracts the jig. [Amy] made it by drilling a bunch of holes close to the outside edge of a circle, and then milled away the edge until she had a fully fluted knob. Once she had the jig finished, she upgraded her honing blocks by milling a new home for them out of milky-white high-density polyethylene.

Mills are fantastic tools to have, but they’re a bit on the pricey side. If you’re just getting started, why not convert a drill press into a mill? Wouldn’t that be more fun that just buying one?

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A Motorized Rotary Shop Table From Scratch

November 20, 2020 by 9 Comments

As we’ve seen over the years, it’s possible to bootstrap your own metalworking shop using little more than a pile of scrap steel, a welder, and an angle grinder. With time and dedication, you can build increasingly complex shop tools until you’ve got yourself a nice little post-apocalyptic workshop. It’s the whole idea behind the [Workshop From Scratch] channel, and we never get bored of seeing his incredible backyard engineering.

But eventually, you’ll have built all the basic stuff. What then? Well, as [Workshop From Scratch] shows in a recent video, you can start working on the luxuries. Do you need a motorized table that will let you spin the workpiece and position it an at arbitrary angle? No, probably not. But as the video after the break shows, it’s certainly a handy thing to have around the shop. We especially like how he uses it to quickly and easily produce nearly perfect circular welds.

Note the welded standoffs used to hold on the lid.

From a technical standpoint, this is perhaps one of his more straightforward builds. But at the same time, the attention to detail that he puts into even this “simple” design is phenomenal. Nothing is wasted, and cutoff pieces from one section are often used in imaginative ways elsewhere.

[Workshop From Scratch] is truly a master of working with what you have, and this project is a perfect example. We especially like the tilt mechanism, which uses a massive leadscrew spun by a wiper motor salvaged from an Audi A8 B4. It looks like a fair amount of new hardware went into the control electronics, but even still, we have no doubt that the cost of this build is well below the purchase price of a commercial alternative.

Much like his hydraulic lifting table or motorized plasma cutter, not everyone is going to need something this elaborate in their home shop. But his magnetic vise and mobile drill press cart are far more approachable for the home gamer. Of course even if you don’t follow along and build your own versions of his tools, it’s always worth tuning in just to see him work.

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Building A Scooter Exhaust From Scrap Metal

June 23, 2020 by 20 Comments

When a part on a vehicle fails, oftentimes the response is to fit a new one fresh out the box. However, sometimes, whether by necessity or simply for the love of it, it’s possible to handcraft a solution instead. [Samodel] does just that when whipping up a new exhaust for his scooter out of scrap metal.

It’s a great example of classic backyard metalworking techniques. The flange is recreated using a cardboard template rubbed on the exhaust port, with the residual oil leaving a clear impression. Hard work with a grinder and drill get things started, with an insane amount of filing to finish the piece off nicely. A properly tuned pipe is then sketched out on the computer, and a paper template created. These templates are cut out of an old fridge to create the main muffler section.

There’s plenty of other hacks, too – from quick and dirty pipe bends to handy sheet forming techniques. It’s not the first time we’ve seen great metalworking with scrap material, either. Video after the break.

[Thanks to BrendaEM for the tip]

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A Home Made Dumper You’d Swear Came From A Factory

June 1, 2020 by 9 Comments

When it comes to YouTube videos, there’s little we like more than some good quality workshop action, watching someone in command of their tools craft a machine from raw materials with an amazing result. It’s something [Workshop From Scratch] delivers with his homemade mini dumper, in which he makes a small dump-truck from scratch with a result that looks as though he’d bought it factory-made from his agricultural supplier.

At its heart is a substantial chassis made from welded together double box section tube, to which he’s bolted a second-hand hydraulic transmission of the type you would find on larger walk-behind groundskeeping machinery. At the back is a front steering axle from a mobility scooter, that pivots on a bearing and wheel hub from a Ford Mondeo to ensure stability on rough ground. There is a platform for the operator to stand on as the little Honda 4-stroke engine moves it around. The bucket is plasma cut and welded, and it’s safe to say that his welding ability exceeds ours.

The result is a machine that looks to be very useful, and dare we admit it, one we wouldn’t mind having a go on. It may not be as powerful as this electric home-built dump truck, but we like it.

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A Twisted Tale Of Woven Wires

May 12, 2020 by 5 Comments

A little over a year ago, we ran a contest that challenged readers to leave the comfort of their PCBs and breadboards. We wanted to see circuits built in three dimensions, with extra points awarded for creativity and artistic flair. Truth be told there was initially some concern that the “Circuit Sculpture” contest was a bit too abstract for the Hackaday community, but the overwhelming number of absolutely gorgeous entries certainly put those doubts to rest.

In a recent video, [Michael Aichlmayr] walks viewers through the creation of his mesmerizing entry Wonderlandscape, which ended up taking honorable mention in the Circuit Sculpture contest for Best Metalworks. Though this is much more than just a simple walk-through of a project. Sure you’ll see how brass bar stock was artfully twisted and wrapped to create a metallic winterscape that looks like it could have come from Bob Ross’s hitherto unknown cyberpunk period, but that’s only half the story.

The brass bar was twisted by hand with pliers.

In the video, [Michael] recalls how he discovered the burgeoning electronic sculpture community, and points to a few exceptional examples that got him hooked on finding the beauty that’s usually hidden inside of a plastic enclosure. Eventually he heard about the Circuit Sculpture contest, and decided it was the perfect opportunity to build something of his own. That’s right, Wonderlandscape is his very first attempt at turning electronics into art.

But the best may be yet to come. [Michael] explains that, due to the time constraints of the contest, he had to use metal stock purchased from the crafts store. But his ultimate goal is actually to melt down salvaged brass and bronze components and make his own wire and rods. We can’t wait to see what he’ll be able to accomplish when he starts working with his own custom made metal, and are eagerly awaiting the future video that he says will go over the techniques he’s been working on.

This story is a great reminder of how stepping out of your comfort zone once and awhile can be a good thing. Entering the contest with no previous experience was a risk to be sure, but [Michael] came out the other side more experienced and with a few new friends in the community. So why not enter our latest contest and see where it takes you?

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Scratch Built Magnetic Vise Stays Where You Need It

May 1, 2020 by 19 Comments

For those who might not have run into one before, a magnetic vise is used when you want to quickly anchor something to a metal surface at an arbitrary position. They’re often used to hold the workpiece down when machining, and can be a real time saver if a lot of repositioning is involved.

[Workshop From Scratch] recently wanted to put together one of these handy pieces of gear, and as we’ve come to expect from his channel, the finished product is an absolute beast. Starting with little more than scraps of metal, the video after the break takes the viewer on a fascinating journey that ends with some demonstrations of the vise in action.

Conceptually, this build is relatively simple. Start with a vise, put a hollow base on it, and fit it with powerful electromagnets that will anchor it down once you flip the switch. Technically you could just build a magnetic base and bolt a commercially available vise onto it, but that’s not how [Workshop From Scratch] does things.

Every element of the build is done by hand, from the pattern cut into the jaws to the t-handle nut driver that gets adapted into a very slick crank. Of particular interest is how much effort is put into grinding down the surface of the electromagnets so they are perfectly flush with the base of the vise. Incidentally, these beefy electromagnets were salvaged from automotive air conditioning compressors, so you might want to add that to your junkyard shopping list.

Eagle-eyed readers might recognize the surface [Workshop From Scratch] uses the vise on as the custom drill press table he built a few months ago. These videos are not only reminders of what you can accomplish when you’ve mastered the use of a few common tools, but just how much design and thought goes into the hardware many of us take for granted.

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