My projects

[Nursepeter1973]

OccupantRJ - Thanks for the compliments and the advice

Ok.. I've just bought a rubber backing disc and 25x 40grit discs from here
So maybe I haven't given up completely.... this should at least scratch the surface... maybe... hopefully

Decided my next project will be a new mount for my HF antenna for the ute as the family and I are driving out to Ayres Rock (Uluru) at Easter (about 1300kms/800miles one way). I had debated on making a full headache rack but I think OoW&F (Office of War & Finance) is torpedoing that idea... Looks like its off to the scrap pile to fashion a decent mount

Basically its three pieces of 90mm angle welded together. The bottom angle will secure to the ute tray via some cuphead bolts.

The difficulty is that the antenna workings (where the joint in the main body is) ideally needs to be proud of any surrounding body work and the fact that the antenna is approx 3m tall... so it must have some decent strength.

 

[Nursepeter1973]

Managed to get out to the shed (actually its a carport) last night.
Followed a boilermaker mates (the guy who donated the workbench plate) advice and heated the area I was intending on drilling with my little MAP gas unit (as I dont own a oxy/acetylene set).. He had recommended heating till it was cherry red but there was absolutely no chance that was going to happen.. So I sat the MAP on there and let it heat as far as it could.. let it cool.. and then managed to drill it all the way through and all the way to 12mm.. score!

Here is my excellent artist impression of how the HF Antenna mount will look on the ute bed (its not my ute, just the same model)

 

[Nursepeter1973]

I've been sitting on my hands for a little bit now waiting for bits and pieces to come in for the next project...
Finally the Makita 14" (355mm) Abrasive metal cutoff saw has arrived and as such I've begun fabricating my headboard.... I went away from the purely HF antenna mount because I think this would be more useful (and more challenging)

The design considerations

• The Barrett Autotune antenna gives its best performance when the entire unit is free and clear of surrounding metal. An issue is that the antenna is 3m high.. I guess it'll be a case of unbolting when necessary
• Cant obstruct vision too much
• Strong enough to withstand the vibration of corrogated roads in the outback (we are travelling to Uluru at Easter)
• Be able to lay longer items in tray against frame and not scratch cab
• Provide protection in event the load moves

Once complete it will likely get powdercoated or painted (undecided yet) (I dont know enough about powdercoat to know if its stronger/more resistant to chips)

Obviously this is the Sketchup of the design.. there will be horizontal infill (50x3mm flat bar)

 

[Nursepeter1973]

Did some setout last night (figuring angles)... and got this far tonight (only allowed to do a couple of hours due to a noise curfew)

Tomorrow nights job is to widen the wiring holes (to do the stop and turning lights).
Loving the new Cutoff saw.. no chance of doing this without it.

 

[Barlow L]

concerning the holes, I'd leave them as well. Three Speaker magnets or the like underneath will close them up so small parts don't fall through.

 

[Nursepeter1973]

A couple of nights later and the outer frame is tacked together...

Time for a test fit...

These are the first true welds on gas with the Mig... they look ok to me.. I'm ready for some harsh criticism... I haven't had any training (other than youtube)

The steel is 65x35x2mm (14ga). The bottom bar is 1530mm long and each side is tilted in at 22degrees.

 

[1/2 Cup]

I would not be ashamed of those welds one bit, well done.

 

[Wes917]

The last two don't look to bad. One tip, knock your tacks down a little before welding. You can see two spots (one on each weld) where you have a lack of fusion by the tacks in the corners. By knocking them down a little you can consume them smoothly.

 

[Nursepeter1973]

Wes917 - Thanks.. you're right the tacks were sticking out a bit so I'll def keep that in mind.

Tonights effort...

Somewhere along the line I seem to have engineered a rollcage more than a simple rack.. the cross bracing kind of evolved.. and I do like to over engineer things...

Tomorrows task - the HF antenna mount off the side.... then its the infill...

 

[Nursepeter1973]

An update on the headache rack (which is nearing completion of the fabricating side of things). All thats left is welding the angled pieces and notching the angle at the bottom.

I thought I would post a picture of my last ditch effort at taking my fabrication bench back to a semi shine.. compared to the black it is....

Here's hoping a 100mm belt sander with 36 grit will do the trick... please let it work...

 

[1/2 Cup]

The rack is coming along nicely, all those angle cuts would be a challenge!
The Makita belt sanders are great, be prepared to use a few belts on your bench top though, speaking from my recent experience.
Cheers.

 

[Nursepeter1973]

Actually the angle cuts weren't too difficult to be honest. With the new chop saw and the judicious use of a digital angle finder all the angles worked out well, except for the central one which required some finessing (laying the chop saw on its side to transfer the angle to the saw fence was my secret). Todays job is doing the install of the rack and the difficult task is grounding the HF antenna.

I spend 5 minutes with the belt sander on the top last night, It certainly removed some surface material. Will see how it performs on a more dedicated session.

 

[Nursepeter1973]

I'm after some opinions on what some of the more educated people on here think regarding some desk brackets I'm intending to make up to support a wall mounted desk.

The top is likely to be a sheet of 20mm (3/4") plywood/mdf and then covered with some Marri flooring. I'm expecting the top to be 30-40mm thick. I am wanting to offset the top approx 50mm from the wall to facilitate power/ computer cordage.

Desk to span two walls approx 3270mm and 3520mm. Brackets to be placed approx 880mm appart one side and 1005mm the other.. the ends with have a support as well as the inside corner.
View media item 46879
The brackets are likely to be made out of 50mm x 3mm thick flat with the cross brace out of 25mm x 3mm angle.
View media item 46876
Approximate look with a section of the top made transparent
View media item 46877
Another angle to show how i intend to place the crossbrace edge on.
View media item 46878
So? Strong enough? Needs another brace?


Ok. Been a bit slow in the project side.. but that is soon to change as the family (and I) will be moving back to Perth come the end of January.... more access to hardware stores (and our own house) makes projects easier.

List of Projects
- New Cubby
- New Study Desk
- Extend attic floor
- Seal Attic (?plasterboard)
- Gazebo to cover spa
- Build retaining wall
- Build pizza oven

I utilise Sketchup for most of my design.. I find it easier. I have the entire house done which makes it good for figuring if furniture will fit.

 

[1/2 Cup]

Firstly, thanks for the update.

That's a big move coming back to Perth, all the best with it.

Sounds like you are going to have a fair bit on your plates over the next few months.

There are heaps of options in terms of your desk, its supporting brackets and they way you set it up for the electrics, data and hide computer cables.

I would consider a moduline style of duct either above or below the desk, this gives you a bit of flexibility where you place the outlets and caters for future life style changes as well.

I will put some more thought into it over the next week or so and drop by again.

Regards

 

[Nursepeter1973]

1/2 Cup - Your contemplation will be eagerly awaited. No huge rush as access to the house isn't available until the end of the month and I still need to get an electrician out to run a line for a 15amp point for the mig... (and a 32amp for the new spa... and a 3phase outlet.. because... who knows what the future brings)... and I'll finally have access to some HCL to see if that takes the brown coating off the top of the bench...

Great idea regarding the ducting. Do you mean something like http://www.ecd.net.au/modules/mastop_publish/?tac=3 or are you meaning something more simple like a http://www.ikea.com/au/en/catalog/products/10200254/ ?

The bracket design was simple as I dont have a lot of tools to make curves etc. I did wonder if a thicker/larger cross brace would be needed or the wall attachment leg made longer. I have some 5mmx 80mm angle iron.. which i might utilise for the inside corner.

Regarding the move... yes a 900k one way trip is a bit of a journey. I've done 4 loads previous to this with a 6x4. I borrowed a mates 8x5 (which equates to nearly double the capacity) the previous load.

Swagman Roadhouse - Mount Magnet (300km from home - 600km from Perth)
View media item 46914
This is the second last load and has broken the back of it (36 boxes, 10 seater table, 10 chairs, tool chest, two bedside cabinets, mig welder and trolley, 6 collapsible 2100mm shelving units and a freezer, plus odds and sods stashes in gaps). I have advised the wife in the strongest terms.. it fits on this next load or its not coming...

Talking of trailers.. I have been frustrated recently with not having adaptors for different peoples trailers (or the fact that adaptors I've bought are dodgy or grow legs...) so last week after moving that load I made this...
View media item 46915
View media item 46916
So... left to right... 7pin round (small), 12pin flat (which also takes 7pin flat) and a 6pin round (small). The 7pin and the 7/12pin flat are now the most common here in Australia

 

[Heavymetalmechanic]

Wow, I do not envy you that move! I thought hauling all my stuff across the city was bad, I will keep my complaints to myself next time.

This projects all look well thought out and properly executed, I am looking forward to seeing what you achieve in the new shop.

 

[1/2 Cup]

That's one serious move.

With the ducting you could utilise both systems very effectively and end up with a neat and tidy work area.
Run the top to the wall without the gap??

With the brackets, provide you have good fixing I would do the following;

Go a 50 x 6 mm all round.
Lengthen the leg some what say to 500mm
Gusset the corner with some flat.

I love your trailer adaptors, thinking out of the box..

Regards

 

[Nursepeter1973]

1/2 - Thanks regarding the size increase.
Do you also mean the crossbrace? I certainly think that would be worth beefing up as it is (to my understanding) the main load bearing unit & also increasing the length of the wall flat to bring the angle closer to 45deg vs the current 60..

My understanding of the wall/desk flat is more there to act as a securing point as within reason the load is transferred into the desk/wall via the cross brace.

The desk offset is desirable as 1) gives the impression of floating 2) I don't like holes in the top.

I've attached an updated drawing of the suggestion.. changed the corner to the 80mmx5mm angle (which I already have - I'll prob add some triangled gussett between the flat and angle joint) and changed the angle cross brace to a 25mm SHS x3mm wall thickness.

Looking at steel prices the 50mmx3 is $18.92 vs 50mmx5 is $30.64... relatively negligible.. though I think I have the 3mm.

View media item 46954
I was intending on utilising 3x 10-12mm Dynabolting (http://www.ramset.com.au/Product/Detail/82/DynaBolt-Plus-Sleeve-Anchors) into the brickwall.

 

[Radio Ron w4ron]

I love your HF antenna, what's your call sign.
Mine's W4RON, I use a Pozy screwdriver on the back of
my '91 Buick Park Avenue. I run a Icom 706 on HF and a Kenwood
dual band for VHF & UHF.
I've worked two Australian station from the car on 40 meters in the
morning just before sunrise.
Below is a pix of my mobile antenna, the mount is made of 1/2"
steel bolted to the body of the car behind the bumper. It's super
strong, I fully believe I could pick up the entire car with it.


73, W4RON

 

[BBChevro]

I just discovered this thread today NP, I love the welding table/work bench.

If I was building that desk, I would just run some light RHS (probably 40mm x 75mm or 50 x 100 if it needs to support more weight) wall to wall (eliminating the brackets altogether - for a cleaner look and nothing to bang your knees on), picking up the wall studs with a flat plate.

It would need to be in from the edge a bit to accomodate the "bite" in the corner.

That's just my opinion - feel free to disregard.

 

[1/2 Cup]

The brace should be ok.

I like your idea of the floating bench, now I see where you are headed.
Fixings should work ok, I was making the assumption you were on a stud wall.

Other than that it looks good, just remember I tend to over do stuff any way..

Regards

 

[jackfork]

Looking for ideas for my soon to be finished shop. Thanks for showing what you have done. Very nice.

 

[Nursepeter1973]

Radio Ron - The unit i have is HF but not HAM. In Australia we have access to limited HF radio where you can operate on specified channels.

BBC - That was a concept that I had originally thought of but wasn't sure of whether it would take the weight. Would you do mitred corners? (I assume). Would be more preferable for the knees issue.

 

[Nursepeter1973]

1/2cup - I prefer to over do things too.. I'd rather make it stronger... Who knows what'll happen.. I'd like it to be able to sit on it. What is your ideas on what BBC said regarding utilising 100 ?? RHS without the crossbar? That would be what I'd prefer - I have seen similar used in garages to hold scrap steel.

Jackfork - Stay tuned I've been in a rental house away from home for the last 3 years... moving back to my own 3 car garage... many more projects... will be a lot more projects to be done.

 

[1/2 Cup]

The are a couple of other solutions that you may want to consider that I have seen here on the forum and will achieve the look you are after that are along Marks ideas.

Let me troll over the next day or so I can't remember where I saw it.

Regards

 

[Nursepeter1973]

Talking of trunking/cable management I am thinking this has my name written all over it.. at the right price at $7/m (its 45mmx45mm).... it also comes in a Large size

View media item 47020
1/2cup - Look forward to idea regarding the non crossbraced brackets. I've seen them around in posts esp when people use them for storing long lengths of steel/wood up on walls. Easy enough to make.. its figuring the appropriate dimension of the steel tubing ...

 

[1/2 Cup]

Talking of trunking/cable management I am thinking this has my name written all over it.. at the right price at $7/m (its 45mmx45mm).... it also comes in a Large size

View media item 47020
1/2cup - Look forward to idea regarding the non crossbraced brackets. I've seen them around in posts esp when people use them for storing long lengths of steel/wood up on walls. Easy enough to make.. its figuring the appropriate dimension of the steel tubing ...

The slotted duct is fantastic for hiding excess cable..

Regards

 

[Nursepeter1973]

Racingtadpole - In reply to your post that either isnt showing or was deleted. Yes I'm a hack and don't know how to make a loom (and in this case I dont want to).The slotted duct is easy and tidy and can be easily reconfigured. Perfect for the changing config of computers/printers/routers/lamps etc

 

[BBChevro]

1/2cup - I prefer to over do things too.. I'd rather make it stronger... Who knows what'll happen.. I'd like it to be able to sit on it. What is your ideas on what BBC said regarding utilising 100 ?? RHS without the crossbar? That would be what I'd prefer - I have seen similar used in garages to hold scrap steel...

.

My wife is always telling me that I over-engineer everything I build too, but I really think that the 40mm x 75mm (that's 1 ½” x 3”) RHS will be plenty strong enough.

I used it for the rails of the "monkey bars" when I built the kids' playground...
View media item 47034
I weigh about 97kg (214 pounds) and can hang from those bars without any sign of movement (from either the bars or me ).
View media item 47036
You can see the size of the tubing better in this one...
View media item 47035
So I don't think sitting on it would present any problems as long as you are able to pick-up some wall studs at both ends.

 

[Nursepeter1973]

BBC - That is a solution I hadn't considered.. great idea but not sure I want to use that much steel from what I assume you mean across the front of the desk.

Current thoughts are something like this
View media item 47039
Bolted into the bricks (the one advantage of living in WA - double brick walls externally and single brick everywhere else - no studding)

Again your idea has merit though...

 

[racingtadpole]

Racingtadpole - In reply to your post that either isnt showing or was deleted. Yes I'm a hack and don't know how to make a loom (and in this case I dont want to).The slotted duct is easy and tidy and can be easily reconfigured. Perfect for the changing config of computers/printers/routers/lamps etc

Dunno where its gone, it was posted from my phone, maybe that had something to do with it. For the benefit of the conversation the comment went along the lines of:

Me taking the piss out of the electricians and instros I work with using slotted cap and case to hide excess cable because they dont know how to make proper looms.

More a social commentary and certainly no offence intended. The stuff has its place, a task as you intend is one of them.

What have you got attached to that Barret as a transmitter?

 

[Nursepeter1973]

Tadpole - Nah no offence taken I know my limitations

The antenna has a Barrett 2050 attached.. well its detached now. Looking to sell as I wont be driving remote (ie Leinster to Perth, Leinster - Uluru (Ayres Rock) etc anymore) Barrett 2050

 

[1/2 Cup]

BBC - That is a solution I hadn't considered.. great idea but not sure I want to use that much steel from what I assume you mean across the front of the desk.

Current thoughts are something like this
View media item 47039
Bolted into the bricks (the one advantage of living in WA - double brick walls externally and single brick everywhere else - no studding)

Again your idea has merit though...

I like the one on the right, its tough.

 

[Nursepeter1973]

That was my original plan.. wasnt sure it was going to be strong enough.. the plan is to cut holes in the face to facilitate a socket to tighten the ramset bolts. That drawing is 65x35mm RHS ?3mm wall

50mm hole near the top to facilitate cable routing with shoulders either side to sit the ducting on (I bought 8m of the stuff I put up earlier)

 

[Nursepeter1973]

Finally putting some pics up of an old bench drill I picked up for $420. A Brombo Waldown Type 8 SN Series III... She has a bit of surface rust but hums quietly along when running. A bit of TLC in order before too long to clean her up a bit. Shes a 5 speed but I'll live with that

View media item 48325
View media item 48326
View media item 47956
The original ?Bakerlite switch.. not sure if I'll update it or not (prob not)
View media item 48327

 

[saceone]

great thread, nice projets !

 

[1/2 Cup]

Great score well done..

 

[BBChevro]

Nice old drill press there and (unless it's broken) I'd keep the switch.

You should post it here... http://www.garagejournal.com/forum/showthread.php?t=116677

My old freebie is there too... http://www.garagejournal.com/forum/showthread.php?p=3995644#post3995644

 

[Nursepeter1973]

Thanks for the tip. Ill check it out

 

[1/2 Cup]

Ditto , keep the switch as is.