Okay, it's been a very busy few weeks so I haven't had a spare second to catch up but I'm going to attempt to now.
Judiaann had a week long trip to NYC with her niece planned and my goal was to finish the bedroom by the time she came back. A very ambitious plan considering that I'd only have two of those days where the kids were in school and the rest of the time I'd be trying to finish while also managing the destructive force of a 4 and 5 year old by myself. There's also the fact that I haven't really "finished" a room yet. Yeah, there's that too.
The story starts with Sean wondering how I was going to keep my drawer pulls square. I was wondering the same thing but being called out in public added to the pressure! I decided that the more difficult part was not going to be the welding but the cutting of the two miters on the stainless. They would be essential.
I was considering ordering some 8020 to rig up a fence system for my cold saw when I discovered that I still have the wings to my Kapex and that they, remarkably, were about the same height as my saw - it must be because they're both German.
The first thing was to make a mount for the wings so I needed to determine the hole center distance. Here's one of my absolute favorite tricks of calipers. Measure the width of the hole you need to find the center between. In this case 8.87mm.
Press the "zero" button to zero the caliper
at that distance.
Now measure from the outside edge of both bolt holes. That's your center-to-center distance. By zeroing the caliper we subtracted one hole's width so the other was divided in half. It's about all the math my head can get around so like a little kid amazed when you pull a quarter behind their ear this trick is endlessly fascinating to me. Wheee! I could do this for hours!!!
I measure the first hole, zero the DRO and then drill two holes with countersinks 120mm apart.
Perfect. Except that I need to add a "V" groove to hold the mount for the Kapex.
For that I grab some aluminum angle which I'd then attempt to weld to the 1" block.
Key word attempt.
It didn't go well. I'm only an aluminum welding novice and trying to weld thick to thin was not going well. I abandoned hope and decided to just buy a thicker piece of aluminum to avoid the trouble. When I got my block home I realized that I had no way to cut it small enough to fit in either the cold saw or the mill. Foiled! At this point I spent more time watching aluminum welding videos and getting frustrated that I may not be able to complete the project in time. Then it occurred to me that I still needed a bandsaw and while I wanted a bigger machine I should consider a smaller one to get me by. Something like a Rockwell/Delta 14" which are ubiquitous and reliable.
With great luck one had just been listed for $250 and I was the first person there, pointed out some issues like missing screws and a loose hinge and loaded into the truck for $200.
Then off to the lego store to buy myself some time with the kids. Lego is almost as good as an ipad for occupying children but it's far more developmentally worthy. And let's face it, more fun for me.
Back home lego was opened and I decide to try welding the aluminum one more time before I threw in the towel and as luck would have it I finally got a bead that was decent enough to do the job. And I got a bandsaw! Sneaky me.
Here's the Kapex wing on the cold saw.
So then I needed to start welding. I do this after the kids are asleep. I used a v-block to hold the round rod and then cut a length of stainless to 500mm - the same width as the closet doors. It's like miniature numerology. I make my first cuts long so that there's room for error.
I weld on one end with two very small tacks on opposite sides then longer welds. I don't add filler and I don't v-groove them - this is a pure fusion weld with low amps. It's a door pull, not a subframe.
From here I clamp the welded end at exactly 90° against a stop measured out to 500mm and then clamp it in the v-block.
This ensures the cut will be parallel to the first one. Or perpendicular. Or just straight. Whatever. I'm tired.
I clamp the one end down and then do my tacks and weld it up and... it's square. Perfectly. Nice!
Next up, to keep the missus happy, I scotchbrite the welds smooth. I'll be honest - it looks better and I give the whole pull a once over to make them look smooth.
I'm like a production facility! Okay, maybe not. But those are done and that's progress.
Gregor