Welding Aluminum With A MIG Welder

October 29, 2022 by Al Williams 36 Comments

Steve Martin had a bit that was like a fake infomercial where he says, “You can be a millionaire and never pay taxes!” The instructions were, “First, get a million dollars. Then,…” [Brandon’s] instructions for how to convert your MIG welder to do aluminum for under $25 is not quite like that, but you do need the right kind of MIG welder to make it work. In particular, you need an actual MIG welder that has a provision to connect external gas. The instructions show a Hobart Handler 140 that meets the criteria and has sufficient power to handle aluminum.

The main task is to replace the liner for the torch. The stock liner is steel which is fine for its intended purpose, but it is too rough for aluminum wire. A PTFE liner is inexpensive and will work fine with the aluminum wire. If you want to do normal welding later, you’ll need to put the original liner back in.

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Nail This Tricky Kumiko Pattern

March 11, 2022 by Matthew Carlson 4 Comments

[Pask Makes] has previously made Kumiko patterns in wood and was happy with the results, but he wondered if he could make something visually similar from metal instead of wood.

For that, he reached for nails as it is a cheap source of uniform small rods of metal. Kumiko is, funny enough, a technique known for joining small pieces of wood without nails. There are many different patterns that use the technique and most are inspired by nature. It is the pressure of the wood in the pattern itself that holds it together and requires dedicated planning and thousands of minute adjustments. Since [Pask] was using a MIG welder to hold the nails together, it isn’t technically Kumiko but rather a Kumiko pattern.

The first step was to take the coating off the nails, which is something a little acid does a wonderful job with. After dropping a little acid, his nails were prepped and he was ready to tack them together. He printed a template on a sheet of paper and used a straight edge and a palm router with a groove bit to cut little channels for each of the nails to sit in. The nails were trimmed to the correct width with the help of a small jig. After he had tacked the nails together, he came back and filled in the centers.

It’s a straightforward little project that creates a beautiful pattern and it’s a good reminder that simple materials can make complex things. If you prefer the wood look, this Kumiko guitar might be more to your taste. Video after the break.

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DEFCON Thermometer

August 5, 2016 by James Hobson 22 Comments

Redditor [mulishadan] — a fan of the movie WarGames — has created a singular thermostat in the form of a Defcon alert meter.

Looking to learn some new skills while building, [mulishadan] tried their hand at MIG welding the 16g cold-rolled plate steel into the distinctive shape. A second attempt produced the desired result, adding a 1/4-inch foam core and painting the exterior. Individual LEDs were used at first for lighting, but were replaced with flexible LED strips which provided a more even glow behind the coloured acrylic. A Particle Photon board queries the Weather Underground API via Wi-Fi in five-minute intervals.

Each escalation in the Defcon alert signals an increase of 10 F, starting at Defcon 5 for 69 F and below, up to Defcon 1 for 100+ F. The final build looks like a true-to-life prop with some useful functionality that can be adapted to many different purposes — proof that a relatively simple project can still produce fantastic results for entry-level makers. So why not try making this thermostat scarf as well?