Thank you all for your support. I've always appreciated the community here and it's always surprised me with its depth and warmth.
Okay, building.
The first thing I did was find the 1/2" bar stock that I'd used when I built the turntable stand. I get a lot of joy when I find I have the right stock in the shop. That is the upside of hoarding. There's a downside obviously. We're just looking at upsides right now.
I didn't measure - I just need enough for a few threads to hold the feet and the tops are solid.
I drilled the bottom ones but didn't tap them because welding will probably mess with the threads so I save that for later. Also, I broke my M8 drill/tap so I ordered another from McMaster. Along with some new feet for the amps.
I can't weld the ends on their sides and welding is all about comfort. I cobbled together this series of blocks and clamps to hold the vertical bars.
The 1/2" bar stock needs a tiny bit of chamfering and relieving on the corners but then taps in snugly. It's really satisfying to tap home. Thinking about it now I should probably have left it proud the height of the tube wall thickness and then added bead but there's no real stress here so I just fusion welded it.
Or tried. My first welds were awful - like there was no ground or no gas. I kept burning the tungsten and finally took off the large gas lens and replaced it with a standard lens. Who knows - maybe there was junk in the argon line because it sat for so long? Maybe I completely forgot how to weld? By the last I was getting into the zone.
I used the short material stop I'd made for the Trennjaeger for the small caps but wasn't sure what I was going to do for the long ones and then saw the aluminum mount I'd made for the Festool Kapex extensions. I'd completely forgot I'd made that partly because it's been forever since I used it and also because I hide them under and behind the Festool cabinets. It was super simple to attach it, square it up and set a stop.
Past me was smart to make that.
I got the four major cross pieces cut and tacked in and the stops got me to within 1mm.
Then I ganged up the tubes and did a super light pass with a big end mill to get them all the same. I like that shot. This is why I like doing this - it makes taking photos fun for me.
And that is where I'm at right now. The front and back frames are tacked together and are square within 2mm on diagonals. My plan is to weld these completely and then add the struts or cross pieces that will make it into a cube. I'm going to make it the same depth as the turntable stand so that when they are next to each other they feel "of a piece" but that also has the added benefit that the gear will be at least a 100mm shorter. That space I'll leave clear so the actual shelves will only span the gear dimensions leaving the cabling, of which there's a lot, free to flow
inside the structure of the box. I bought MDF and some more teak veneer (only enough for the two sides and the top - holy cow is it expensive!) and then birch veneer for the interior shelves which will be stained black. In fact I plan to veneer the inside facing exterior panels in birch stained black as well so when assembled the only thing you'll see is the green back light of the amps and all cables will be hidden. A true black box. With teak sides and top.
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This week is both Thanksgiving and my birthday - typically celebrated as one. The plan for a few months was to head to Moab for Thanksgiving with my brother, sister and family - a tradition we used to do when I lived in NYC. Last week Sacha's wife's father went into hospice (dementia) and then Sacha caught Covid, then his wife Diane caught it. So what was supposed to be a family gathering is now just me, Nadia and Lucas by ourselves in Moab. I was going to cancel but Sacha talked me out of it saying that no matter what a change of scenery and routine would be good. He's right.
The kids didn't want to go on our own but I told them if we stayed it would be the same as the week before and the week before that. Portland teachers have been on strike for three weeks now so this week isn't exactly the holiday "break" it would normally be. I asked the kids to list out all the memories they had; camping, trips to the coast, skiing, going to Colorado and finding fools gold, a rain storm so bad we had to return to town because our tents flooded. I then pointed out that zero of their memories were "staying home and watching Youtube on the ipad."
Even the disasters were good memories - better actually.
Gregor