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Above 1200 Sq/FT Restored 1930's Auto Shop

Wokspaces above 1200 squarefeet.

Rothammel

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Feb 21, 2013
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5
Part II - 2012, What a Year it Was.

...

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The jack stand storage shelve unit (say that fast three times!) helps keep the barn tidy and works as well as I'd hoped.

...

a nice idea you have here with jack stands, I have also built a shelf

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:)
 
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littlebritishcar

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This thread is awesome! I really like the jack stand cabinet. I had an old gym locker that I put my jack stands in but they didn't fit very well.
 
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BB767

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Continuing now with the latest shop project which also involves shelves appropriately enough.

The angled shelf brackets previously completed are going in the barn above the painted bench. More on them later.

The project that I was really, really looking forward to though, was the other set of shelving units that were fabricated for the old shop after I finished the angle brackets. I've been thinking about this project for several years, just mulling it over in my mind. One unit in particular I wanted to get done right.

Now stick with me, here's a little background information on how that shelf unit evolved.



In the lift room was this shelving unit, circled yellow...



...which Mr Johnson had made that held the various vehical shop manuals.



This is a little better view of that shelf unit as the shop restoration progressed and the room and shelves were cleared of objects.



It was the only shelf unit like it in the whole shop.



Made of round, scrap steel pipe...



... with wood shelf boards notched in the corners to fit. Tabs were welded to the pipe and used as mounting points seen here near the top, right. I was always struck by how simple and effective the design was and tucked the concept away.



As cleanup work in the shop continued, I uncovered this blue shelf unit above his cleaning/solvent tank. Seen circled on the right is 1 of his 3 red, oil storage/dispensing tanks.



So this is that same area now with my solvent/cleaning tank and Mr Johnson's red oil tanks still in the same spot they always were. I've been contemplating what to do to replace the old blue shelf unit that was above his solvent and oil tanks. I didn't reuse the original blue shelf because its design consisted of small cubby holes and wasn't very flexible or useful. I eventually came up with what I feel is a more appropriate and useful replacement.

Here's how it was fabricated. This isn't intended to be a welding tutorial, just some thoughts on how I approach a project like this.



Unlike Mr Johnson's use of round pipe, I used 12 gauge, 1" (2.4 cm) square steel tubing which was much easier to work with. After the tubing is cut to length, it's good practice to orient the tube seams all in the same direction. Seen above, the three tubes in the center, right, have the seams facing up and the seam on the left tube is facing down.



Now all the seams are facing up.



I used the Potable Dirty Room, PDR as a fabrication platform for these shelf units. It's a large work surface, stable and its 3/4" (1.9 cm) thick steel top is dead flat and I need a flat surface to keep the work square.



The corner jig (bottom left) was used, clamping the jig to the PDR and then clamping the tubing to the jig.

\

I used a carpenters framing square (yellow) on the opposite corner to square that corner up. The piece of railroad iron was placed on the corner to keep it flat. As the various clamps were added it can tend to lift the work off the work surface if it wasn't weighted down. Note an additional cross piece in the centre of the rectangle. An adjustable square helped position it before it was clamped. Taking time to make sure everything is square to begin with will pay off in a final project that is square and plumb.



All the corners were tack welded first and then final welding done. Move around while welding the unit, don't do all the welding in one corner at a time. Too much heat in one area will tend to warp the whole unit. After all the welds are done wait a minute or so before unclamping to let everything cool and stabilize. Don't be in too much of a rush. The completed end unit...



...was used as a jig for the other end.



I believe in using lots of clamps. The clamps don't have to be super tight, just snug. Get them too tight and they might warp the unit. All the clamps do is hold everything in place while it's welded.



After the two end units were done the long, face cross pieces were welded in place. Here, the long shelf frame on the bottom, has already been welded in place.



Scrap angle pieces were temporally clamped in place to position the cross pieces before welding them.
This was all TIG welded and I did use...



...some of Mr Johnson's welding rod that I found, left in the shop.



I used his #308, 1/16" (.158 cm) stainless steel rod, wiped down with steel wool to remove contaminates.



The single, clamped tube across the very top was used to stabilize and square the ends while the cross tubes were welded in place



This shows the unit oriented as it will be installed.



It is all ready to be powder coated. You can see the next shelf unit is cut and waiting on the PDR. It'll be slightly different. To be continued.

Thanks everyone for your interest and continuing support. ;)

Thomas
 

Rhinotoyz

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Feb 9, 2010
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Hi Thomas and Chris

Wow...378 pages and 7727 posts....I guess if had started reading this thread back when I joined I would have only had to read 29 pages!!:lol_hitti I am simply amazed at what you both have accomplished here. A true labor of love in every respect. This build drew me in like no book I've ever read! My hats off to you guys and enjoy your retirement, you have truly earned it! Thank you so much for sharing!

Jamie

I did have a couple of questions though (after I re-read the first 92 pages AGAIN!! to find my answer)...

How hard was this to get out of the ground or did you just cut it off?

[QUOTE
EastSide05sm-5.jpg


And...
And is it just me or is this crooked?:dunno:


SoundSyssm2.jpg


[/QUOTE]

PS...I was so happy when you adopted Gus!:)
 

impala4speed

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Location
Youngstown, Ohio


It is all ready to be powder coated. You can see the next shelf unit is cut and waiting on the PDR. It'll be slightly different. To be continued.

Thanks everyone for your interest and continuing support. ;)

Thomas[/QUOTE]

Maybe not a welding tutorial but a great fabrication tutorial. Thanks for taking the time to take the pictures and display them here for us. Can't wait to see the final product.
 

markviii

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east central IL
So, Rhinotoyz, thanks for posting in here choosing our thread for your first post. We're honored that you found the reading compelling enough to do so. Better late to the vortex than never! But starting to stir the pot again? Shame, shame. Better think of something nice to post from your garage to add to the thread (or a link to your build. Oh, wait - only one post. Maybe we can be your inspiration to work on or show your garage in a new thread.)
Welcome to our world. (just poking fun)

Chris
 
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BB767

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I did it!
I just finished reading all 7716 posts! What a thread. There is so much useful information in these pages, I don't remember how many things I have bookmarked for later use. The Green Hinge product is just the latest example. Thanks Thomas and everyone else for sharing!


Well?
What can a person say?
WOW WOW AMAZING!
Thanks for sharing!!!!

Thomas and Chris,
I just made to to the end. I must admit I didn't read every word. Mostly just your replies and every post with pictures. I have been truly sucked in and am so looking forward to the home construction phase of the project. Congratulations on living your bliss and all the fun you seem to be having and for sticking together all these years. I am very much on a different end of the journey than you but hope to have as much fun following my dreams. Best of luck and best wishes on what the future holds.

Also I too must echo Joe, I wanna know what else is in that tool shed.:eyecrazy::dunno::bounce:

Greetings to our newest friends. I feel strongly that anyone who takes the time to read most if not all of our postings deserves a personal welcome. It is gratifying to know you don't think it was a waste of time. I'm merely posting about what I'm doing or have done. You can take as much or as little from it as you wish.



Here's a picture from yesterday of the tool shed. It's buried in several inches of snow at present with the doors solidly frozen shut and no significant warm up in sight! Nasty winter this year but I too want to recover the remaining items from there and wrap up that chapter of this story.

Remember, life is all too short, live the life you want to live. :thumbup:

Thank you for your interest. For better or worse, more is on the way.

Thomas
 

oberst

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Nip/tuck....

.... and ready for rock and roll!
 

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BB767

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a nice idea you have here with jack stands, I have also built a shelf


DSC_0572.JPG




:)

Rothammel, well done sir! It looks like you used some left over scrap material too, so the cost of your storage unit is only in your time.
I've had mine in use for a couple of years now and I've been very happy with it and I bet you will too.
Placing that candy machine on top is perfect as well. Great idea and nice workmanship overall.
Thank you for posting all those pictures. I never thought that design would wind up in Germany!
I'll admit it, I'm greatly honored. :bowdown:

Thomas
 
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BB767

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Re: Nip/tuck....

Posting my greetings, hello!....

....Simply great stuff, thanks so much for sharing your project, and your lives, really! It's all inspiring, in so many ways.

ps. how's that switch cover thing going? You still OKAY with it? From someone who has spent hours...days even, leaving and coming back to a stubborn set of switches or outlets to get them JUST SO, I can relate. Perhaps we can all start a "Cover-plate-screw clocker's support group." ;)

Hi Thomas and Chris

Wow...378 pages and 7727 posts.... A true labor of love in every respect. This build drew me in like no book I've ever read! My hats off to you guys and enjoy your retirement, you have truly earned it! Thank you so much for sharing!

Jamie

I did have a couple of questions though (after I re-read the first 92 pages AGAIN!! to find my answer)...

.... it just me or is this crooked?:dunno:


SoundSyssm2.jpg

PS...I was so happy when you adopted Gus!:)[/QUOTE]

He is never going to live this one down....LOL:bounce:

.... and ready for rock and roll!

You know what; first off, little did I know that my abysmal failure at being able to install a simple, straight and square switch cover plate would attract sooooooooooooooo much attention. :eek:

It looks as if the one thing I'm destained to be remembered for years from now is "Hey you remember that Thomas guy from Garage Journal? You know the one I'm talking about, that airline pilot guy who was so messed up he couldn't even install a stupid cover plate straight. :wtf: How lame is that?!!!!!!" But that appears to be my fate. :sad:

That cover plate has gotten such notoriety, that's one of the FIRST items folks ask about when they come for a shop tour. Everybody wants to see it in person. They take a moment to look at it and invariably the response I get is, "yup, it sure is crooked isn't it?" and then I get THAT look. The look that implies "are you kidding me, that's the best you could do????"

So there we have it, Thomas the dumb, retired, former airline pilot, who can clock a screw with the best of them but doesn't have brains enough to figure out how to properly install a simple, easy-peasy switch cover plate.

Thank you all for keeping the legend alive. I owe you one!

Legendary (in his own mind) Thomas
 
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BB767

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I did have a couple of questions though (after I re-read the first 92 pages AGAIN!! to find my answer)...

How hard was this to get out of the ground or did you just cut it off?

[QUOTE
EastSide05sm-5.jpg

I almost forgot your other question Jamie. That lift cylinder which was outside, in back of the shop,...



...was identical to this one from inside the shop. I didn't want to leave it in the ground so to remove it I had a backhoe dug it up. It was a pretty deep hole.



It use to be located about where that small tree is.

Thomas
 

gasgas17

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Nova Scotia, Canada
"You know what; first off, little did I know that my abysmal failure at being able to install a simple, straight and square switch cover plate would attract sooooooooooooooo much attention.

It looks as if the one thing I'm destained to be remembered for years from now is "Hey you remember that Thomas guy from Garage Journal? You know the one I'm talking about, that airline pilot guy who was so messed up he couldn't even install a stupid cover plate straight. How lame is that?!!!!!!" But that appears to be my fate.

That cover plate has gotten such notoriety, that's one of the FIRST items folks ask about when they come for a shop tour. Everybody wants to see it in person. They take a moment to look at it and invariably the response I get is, "yup, it sure is crooked isn't it?" and then I get THAT look. The look that implies "are you kidding me, that's the best you could do????"

So there we have it, Thomas the dumb, retired, former airline pilot, who can clock a screw with the best of them but doesn't have brains enough to figure out how to properly install a simple, easy-peasy switch cover plate.

Thank you all for keeping the legend alive. I owe you one!

Legendary (in his own mind) Thomas"


As a long time renovation contractor I have to deal with this all the time Thomas. We spend a lot of time disguising a multitude of sins. We recently sided a house in Halifax that had survived the Halifax Explosion. It was easily 6 inches out of plumb over 2 stories. It is very easy to see that the switch plate is actually pretty straight. It's obviously the old existing siding that is not level. So do you install the switches level, on the same plane as the siding or split the difference. Neither answer is the right one for everyone. Carry on sir, very fine job as always. Btw, your shelf project inspired me the make some nice hangers for my air hoses out in the shop on the weekend.

Rea%20vise%20004-L.jpg


Rea%20vise%20006-L.jpg
 

GT-TX

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Georgetown, Texas
Thomas:
You may have seen the 1955 photo in downtown Portland, Oregon of the Pigeon Hole Parking system.


Here's a modern day version of the sky garage/lift which is fun to watch. Great place to park your Lamborghini! The video takes just over 2 minutes to watch and is pretty slick! It doesn't quite offer the comfort that "The Center of the Universe" does but at least we now know how "the other half" lives.

http://www.chonday.com/Videos/parking-lamborghini-sky-garage-singapore

After watching the video you might think, "Life is rough for some guys" but that guy driving the Lamborghini and living in the high rise condo in Singapore doesn't know the thrill of driving Texas Hill Country backroads surrounded by bluebonnets in a Model A Ford with the windows rolled down and hearing that hefty 40 horsepower 4 cylinder engine going "ta-puckita-puckita-puckita-puckita". I'll stick with Henry's Lady.

Fred
 
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4AudiQ

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Nov 30, 2012
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167
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PDX
Thomas:
You may have seen the 1955 photo in downtown Portland, Oregon of the Pigeon Hole Parking system.


Here's a modern day version of the sky garage/lift which is fun to watch. Great place to park your Lamborghini! The video takes just over 2 minutes to watch and is pretty slick! It doesn't quite offer the comfort that "The Center of the Universe" does but at least we now know how "the other half" lives.

http://www.chonday.com/Videos/parkin...rage-singapore

After watching the video you might think, "Life is rough for some guys" but that guy driving the Lamborghini and living in the high rise condo in Singapore doesn't know the thrill of driving Texas Hill Country backroads surrounded by bluebonnets in a Model A Ford with the windows rolled down and hearing that hefty 40 horsepower 4 cylinder engine going "ta-puckita-puckita-puckita-puckita". I'll stick with Henry's Lady.

Fred

Links do not work.
Amazing transformation!
 

Vernmotor

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We will just nick name you "the switch plate man " lol NO just Joking, But you did it to yourself by posting it to start with..We needed one thing to pick on you about..so your human :)
 

GT-TX

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Messages
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After watching the video of the "Lamborghini being parked in the high-rise Singapore sky garage" (link below):

http://www.chonday.com/Videos/parking-lamborghini-sky-garage-singapore




You might have asked what does a unit in the Hamilton Scotts En-Suite Sky Garage Luxury Apartments in Singapore cost? Here's what the "Hi Consumption" website tells us, "Living in the city is great, but urban dwellers know all too well what a pain in the *** parking can become. Well the team at real estate development company KOP Properties in Singapore had an innovate, yet expensive, approach to the problem with their en-suite sky garage.

Currently the En-Suite Sky Porches are residing within the Hamilton Scott luxury private residence in Singapore, and these things are absolutely stunning. The garage system shuttles your vehicle up an elevator parking them right inside your living room. Security precautions have been taken in the form of a fingerprint scanner over an encrypted system to ensure no one can steal your vehicle. So how much does this type of luxury cost exactly? Well a luxury apartment with two park spaces will set you back $7.5 million, while a penthouse house equipped with a four car garage will cost you about $24 million." :shocking:

Well, if you can afford a $24 million condo, I guess a $400,000 Lamborghini is just chump change. Thomas, how many '64 Impala Super Sports or powder coated projects could $24 million buy? Thanks anyway, life at the COTU has to be better, right?
Fred
 
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Bob Heine

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Well a luxury apartment with two park spaces will set you back $7.5 million, while a penthouse house equipped with a four car garage will cost you about $24 million." :shocking:
That would be cheap in Mumbai (formerly Bombay), India. This bungalow in Mumbai is going for $32,120,234. In Rupees, that's RS2,000,000,000. Needs work but I think Thomas could turn it around in no time....
MumbaiFrontElevation_zps75e9746d.jpg


MumbaiBackyard_zpse6c6e7ed.jpg


If you'd like to make an offer, here;s the link: http://www.realtor.com/internationa...andy_Mumbai_Maharashtra_IN_3685085?source=web
 
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BB767

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....

As a long time renovation contractor I have to deal with this all the time Thomas. We spend a lot of time disguising a multitude of sins. We recently sided a house in Halifax that had survived the Halifax Explosion. It was easily 6 inches out of plumb over 2 stories. It is very easy to see that the switch plate is actually pretty straight. It's obviously the old existing siding that is not level. So do you install the switches level, on the same plane as the siding or split the difference. Neither answer is the right one for everyone. Carry on sir, very fine job as always. Btw, your shelf project inspired me the make some nice hangers for my air hoses out in the shop on the weekend.

Rea%20vise%20004-L.jpg


Rea%20vise%20006-L.jpg

Greetings gasgas17 and thank you for your post and pictures. Yeah that switch plate thing has really taken on a life of its own hasn't it? As you well know, everything is a comprise when it comes to old buildings. To make it look better I wanted the cover plate to parallel the siding, which, as you point out isn't all that level, but after messing with it for far too long I just accepted the fact that Mr Johnson wanted it crooked and made peace with myself over it. If it were in my house that would be a different matter all together but out in the old shop, well...... not so much. Pick your battles.

As for your hose hangers, very nice, simple and a good color choice. I like efficient and effective designs. :thumbup:


We will just nick name you "the switch plate man " lol NO just Joking, But you did it to yourself by posting it to start with..We needed one thing to pick on you about..so your human :)

Trust me, nobody here ever need worry about my being human and the failings that go with that. Anyone who would transport a several months dead possum in their shinny sports car.............:eek:

A much wiser now and very human Thomas
 
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BB767

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Very nice....Subscribed..!!

Hi there handyman and thank you for the kind words and support. I think you'll like it here; it's just a bunch of great people hanging out and sharing ideas. Invite all your friends, we've got room for them.

Thomas

Congrats Thomas on making the front page again with your jack stand storage unit!

That is the second time, right?

Well until you brought it up I didn't know, but I believe that is correct. And that picture Ryan posted is my best side too! :D

Thomas
 
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BB767

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After watching the video of the "Lamborghini being parked in the high-rise Singapore sky garage"......

.........Well, if you can afford a $24 million condo, I guess a $400,000 Lamborghini is just chump change. Thomas, how many '64 Impala Super Sports or powder coated projects could $24 million buy? Thanks anyway, life at the COTU has to be better, right?
Fred

Ya know Fred, Chris and I are just so happy here. While it's fun on occasion to see that kind of "stuff", I wouldn't trade places with anyone. As someone once put it, "It's not having what you want, but wanting what you have".

Philosopher Thomas

That would be cheap in Mumbai (formerly Bombay), India. This bungalow in Mumbai is going for $32,120,234. In Rupees, that's RS2,000,000,000. Needs work but I think Thomas could turn it around in no time....
MumbaiFrontElevation_zps75e9746d.jpg



If you'd like to make an offer...............

Well sure I could. It just need a little TLC is all! Thanks for the vote of confidence Bob.
That kind of money for THAT property is just breath-taking isn't it?! Philo's looking better to me allllll the time. ;)

Thomas
 

GT-TX

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Thomas:
Since you are now retired and don't have anything else to do, try the following:
A few days ago my best friend from high school sent me a 'Viet Nam Veteran' cap. I never had one of these before, and I was pretty hyped about it, especially because my friend was considerate enough to take the time to send it to me. Yesterday, I wore it when I went to Wal-Mart. There was nothing in particular that I needed at the world's largest retailer; but, since I retired, trips to Wally World to look at the Walmartians is always good for some comic relief. Besides, I always feel pretty normal after seeing some of the people that frequent the establishment. But, I digress... enough of my psychological fixations. While standing in line to check out, the guy in front of me, probably in his early thirties, asked, "Are you a Viet Nam Vet?" "No," I replied. "Then why are you wearing that cap?" "Because I couldn't find the one from the War of 1812." I thought it was a snappy retort. "The War of 1812, huh?" the Walmartian queried, "When was that?" God forgive me, but I couldn't pass up such an opportunity. "1936," I answered as straight-faced as possible. He pondered my response for a moment and responded, "Why do they call it the War of 1812 if it was in 1936?" "It was a Black Op. No one is supposed to know about it." This was beginning to be way fun! "Dude! Really?" he exclaimed. "How did you get to do something that COOOOL?" I glanced furtively around me for effect, leaned toward the guy and in a low voice said, "I'm not sure. I was the only Caucasian on the mission." "Dude," he was really getting excited about what he was hearing, "that is seriously awesome! But, didn't you kind of stand out?" "Not really. The other guys were wearing white camouflage." The ***** nodded knowingly. "Listen man," I said in a very serious tone, "You can't tell anyone about this. It's still 'top secret' and I shouldn't have said anything." "Oh yeah?" he gave me the 'don't threaten me look.' "Like, what's gonna happen if I do?" With a really hard look I said, "You have a family don't you? We wouldn't want anything to happen to them, would we?" The guy gulped, left his basket where it was and fled through the door. By this time the lady behind me was about to have a heart attack she was laughing so hard. I just grinned at her. After checking out and going to the parking lot I saw Dimwit leaning in a car window talking to a young woman. Upon catching sight of me he started pointing excitedly in my direction. Giving him another 'deadly' serious look, I made the 'I see you' gesture. He turned kind of pale, jumped in the car and sped out of the parking lot. What a great time! Tomorrow I'm going back with my Homeland Security cap. Whoever said retirement is boring just needs the right kind of cap!
Fred
 

MetalMangler

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That's just too funny.

It's like the joke of the old man who comes out of a store to find a parking enforcement officer writing a ticket for the car at the curb. So the guy starts giving the officer a ration of grief that he'd only been in the store for a minute... The officer just starts to write another ticket for dice hanging from the mirror (view obstruction). So the guy starts really giving the officer an earful. Finally after the officer writes a slew of tickets the old man walks off and gets on the city bus. It wasn't his car, anyway!

Just a couple of ways to pass the time once retired. :-D

MM
 

85cobraGT

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Corvette Museum sinkhole swallows cars whole

http://www.cbc.ca/news/world/corvette-museum-sinkhole-swallows-cars-whole-1.2533800

what are the chances of this happening?
i thought of this thread and all the Corvette enthusiasts as i read this story, how sad.

Tom, i just realized the only other time i posted here (post #3173, page 159) was about that pesky airline that ran behind your new beautiful butcher block-top barn bench (BBBBB) that i see you discreetly placed a bubble gum machine (BGM) in front of...i have no idea why everyone makes such a big deal about the switch cover plate in the old shop all the time! I feel this deserves some attention as well!:lol:
 
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BB767

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Corvette Museum sinkhole swallows cars whole

http://www.cbc.ca/news/world/corvette-museum-sinkhole-swallows-cars-whole-1.2533800

what are the chances of this happening?
i thought of this thread and all the Corvette enthusiasts as i read this story, how sad.

I've seen the video and am just astonished. Even Hollywood couldn't make something bizarre like that up. Totally, completely unbelievable. Who ever carries the museum property insurance must be denial over the whole thing. And why did it have to be the Corvette Museum of all places?! :sad:

Speechless Thomas
 
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BB767

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I almost forgot in all my Corvette grief; has anyone responded to mister honey- (Mike) and asked for Beltsville Shell? I'd like to get a couple more readers to sign off in it before Chris and I head west. It's only a few hours read and if you're a car guy or gal I can guarantee you'll like it.
Mike if it's been sent to someone can you post their GJ name here please? Thanks much.

Thomas
 

markviii

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85cobraGT - Something like life mimics fiction. Very strange, but very real. Luckily no one was in the room when the cars began sinking. Hope they can stabilize things so no more cars or building are lost.

MetalMangler -I read that story sometime this week. Very funny!

I haven't had any time or need to find things to amuse me in my retirement. Life is busy enough! And Tom has seemed to put himself into a schedule that works for him. Sure is nice to not "have" to be someplace unless he wants to be there.

Chris
 

gordyy

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North Dakota
I believe I commented on the switch plate once before but have my own story to tell.
years ago remodeling my mother in laws house I was re doing her bathroom had pressure as a dear friend of hers had a birthday party coming up. The host of said party had gotten sick, I was called on Thursday and notified the bath needed to be finished by Monday. I went Saturday after work (had my boys 11 and 12 load up the van while I was at work got down there finished the wiring thought those boxes do not look right checked again, drywall went on finished painted loaded the truck late Sunday night. Went to work on Monday got my level out of the truck noticed a large scuff on the corner, turns out my angels were playing toss the tools from one vehicle to another to load up for the run to grandma's place guess what got dropped from a 25 ft. throw. I and of course IT runs down hill my son's get a good ribbing every time someone goes in the bathroom funny how a triple box with others 16 inches away can look so bad if you know they are off
 

jwh

Well-known member
Joined
Aug 10, 2005
Messages
774
Location
Rochester NY
Thomas, don't beat yourself up over the light switch.

True story: One of my co workers remodeled his living room. Next door neighbor comes over to check finished project. Says "Jim your light switch is crooked." Jim says: "Ron, I know, that's as straight as I can get it." ( I also know him, we both have the same previous employer.)

2 hours and 5 trips to his house for parts later, Ron had the light switch straight.

Seriously, great job on everything!

John in Rochester NY.
 

56vette461

Well-known member
Joined
Jan 13, 2013
Messages
491
Location
Northern California
Thomas, your light switch plate has taken on a life all it's own.

The alternative answer jwh's friend could, "No Ron, the house is not plumb, the wall ain't square, and I'm leaving it for the builder to live with. That switch plate is the only thing in place that is square to the world."

I also have one light switch plate that has a screw that is turned to the 2 o'clock position, just to screw with my nosy neighbors head. Every other screw is straight up 12. It drives him nuts. He threatens to get a screw driver and fix it himself. It is good for a laugh.
 

RPageOne

Member
Joined
Apr 20, 2013
Messages
19
Location
DFW
Well Thomas, you have created quite the environment to enjoy life. Great read. From Mr. Johnson’s life & creations on site, to the Willys, to the BBB, education on Sycamore (which we had in East Texas & I climbed as a boy), to lumber racks, on to Bob’s story and his sawmill, then oh my was the intro to Earl was great. I have no intention of attempting the Chris challenge test as I have my very own retired teacher providing all the "test" I can handle. You are just an amazing story teller. As a life long GA pilot with 4,000 hrs. or so I had great interest the entire trip. Enjoy this phase as you deserve it.
 
OP
B

BB767

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Joined
Dec 24, 2009
Messages
3,724
Location
Philo, IL
With the barn shelf brackets done and one of the shelf units for the old shop completed, here is the fabrication of the second shelf unit.

I use a Speedglas auto darkening welding helmet that I've come to love. It works very well and I've only had to replace the battery once in the last 7 years. Another convenient welding feature is having an all metal welding table. Because of that I attach the ground cable to the table and don't have to attach it to the work itself.



Starting with two rectangles...



...these were the end pieces...



...that were attached with long...



... horizontals tubes.



Here you can see the corner jig used to help square the upright ends with the horizontal tubes.



To check the upright ends for square, I ground off the outside corner of the framing square...



...so the square would bridge over the weld bead on the inside corner.



To stabilize the upright ends before they were welded, the upper horizontal tubes...



...are being temporarily clamped in place.



A scrap piece of angle is used to position those horizontal tubes.



To help hold one of the lower horizontal tubes, this bridge set up, closest to the camera, was used.



This held the lower horizontal tube in place but still left the inside corner exposed enough...



...so it could be welded.



After all the welding was completed this is the basic shelf unit with a reinforcement brace in the middle of each shelf.



Next step was to roll the PDR outside. Note the snow in the background. It was mid 20's F while I was grinding welds.



That's not oil on the concrete BTW, but melted snow.





Clamping the work to the PDR while grinding welds makes it much easier.

With all the welds ground and looking good it's................off to Rick's for some powder coating. :D

Next up, some wood working. Check back to see if I still have all my fingers when I'm done. Thanks everyone.

Thomas
 
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jwh

Well-known member
Joined
Aug 10, 2005
Messages
774
Location
Rochester NY
The alternative answer jwh's friend could, "No Ron, the house is not plumb, the wall ain't square, and I'm leaving it for the builder to live with. That switch plate is the only thing in place that is square to the world."

I also have one light switch plate that has a screw that is turned to the 2 o'clock position, just to screw with my nosy neighbors head. Every other screw is straight up 12. It drives him nuts. He threatens to get a screw driver and fix it himself. It is good for a laugh.

Sounds like your neighbor and Ron are from the same mold.

First day back to work, I told Jim that his light switch story has made it to the internet. He said practically what you said..The house is 90 years old, nothing is plumb or level except the light switch.

Knowing Ron, now it really is level.
 

dhickey79

New member
Joined
Dec 1, 2012
Messages
1
WOW! What an amazing process! Thank you very much for sharing all of this...it took quite awhile to read through it all, but well worth it.
 
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