Now that we have a build table, the next step is to build something on it. A trip to the local metal supplier got me a decent deal on 1x1" 16ga, though they only had four sticks of it at the time. Enough to get me started, so game on! I took the future donor vehicle to pick up the sticks. Cut in half and with an abundance of ratchet straps, I got them home without trouble. My dad let me do a long-term borrow of his old horizontal bandsaw (that very badly needed a tune-up) and my grandpa had an old 120v flux core welder he didn't need. Add in a combination belt/circular sander I picked up a few months back and it was time to get building.
Attachment:
SteelInTruck.jpg
I know many, many builders have had good luck using strips of wood screwed to their table to secure their bars before welding, but I had an idea kicking around in my head for some time. I enjoy 3D printing and wanted to make a bunch of brackets to screw the tubing to the table. I am still uneducated in 3D modeling software, so I drew up my idea and sent it to a buddy to see if he'd be willing to make it in CAD. About two minutes later, he sent me a file and I got busy printing.
Attachment:
PrintedBrackets.jpg
These 3D printed brackets worked better than I ever could have imagined. Using drywall screws, they give a very snug fit to the steel, but I can still tap it with a hammer to make very minor adjustments if needed. Plus, I could print enough of them to secure the chassis to the table and hold things in place when I weld. Once I got the bars laid out and secured, I threw down my first few (UGLY) tack welds to hold things in place. I was so excited about building this simple box, I could hardly sleep that night.
Attachment:
InitialBox.jpg
The following nights led to more pieces getting cut, sanded to length, laid out, screwed down, tweaked, tweaked some more, measured for squareness, and giving a quick zap with the welder. It was so much fun to see the initial pieces coming together and the bottom of the chassis getting laid out. At this point, pretty much all of my "mindless time" (driving, mowing, pretty much anything that I can zone out a bit) is filled with thinking about which tube to cut next, how to cut compound angles, and tools that would make things go more smoothly.
Attachment:
SecondSection.jpg
I was a little nervous about my precision as I could never get exact cuts when working with wood on various house projects around the house. I could always get my cuts close, but even marking lines with a knife and being careful with saws, I just wasn't happy with the outcome. Thanks to the metal bandsaw and sander to bring the angles and length to where I need it, I was thrilled when I got the bottom rails done and was within about 1/20th of an inch of being perfectly square. I know welding will likely push and pull some of the metal, but getting that squareness made me feel pretty proud.
Attachment:
BottomTubes.jpg
The final step was bringing out the shop crew to check out the progress (Sorry, not sorry if you're already tired of kid pics.) They even stole my thunder by taking the car for its first drive.
Attachment:
FirstDrive.jpg