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Metalworking Badge Oddball Thread

BB metalworking - wood badge
 
steward
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Location: Northern WI (zone 4)
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Some PEP badges allow for oddball points.  This was introduced in this thread.

When submitting something in the official Oddball badge, you get points based on the time it would take a professional to do the same task if they have a bit of luck.

When submitting something within a badge that allows oddball points (Homesteading, Metalworking, etc), they are based on the time it would take a talented newbie to do the same task.

When you did something that should be in a badge but there isn't a BB for it, post about it in that badge and maybe it will become a BB.  If that badge allows oddball points, you can submit it there, otherwise it has to go into Oddball badge.

Some examples:
You welded up a 20 foot unicorn - put it into the Metalworking Oddball thread
You made a candle - put it in the regular Oddball thread since it isn't a clear fit for an existing badge
You build a pump house - post it in Homesteading since it should be a BB there and/or put it in Homesteading Oddball
 
gardener
Posts: 267
Location: NW Washington - Zone 8a : 10 to 15 (F)
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Approved BB submission
Otis wants to hang things on walls with confidence they will not fall off, and to do it without glue or paint or an Amazon purchase, right?  The wall clock I made using the end of a used wine barrel was apparently too heavy for the store bought picture hanging bracket and it bent and broke.  Luckily I noticed before it fell off the wall and did some damage.  So I decided it was time to fabricate a beefy steel hanger for it that I guarantee won't fail!


Bent and broken store bought bracket.


Raw materials for making a new bracket.


Parts dilled, cut out, and edges ground smooth.


Ready to weld.


First weld.


Next weld, still red hot.


Test fit.


Bracket installed on wall.


Lag installed on back of clock.


Clock hung back on wall.


Staff note (gir bot) :

Someone flagged this submission as not complete.
BBV price: 3
Note: Same job posted/approved already: https://permies.com/wiki/140/97787/pep-oddball/PEP-Badge-Oddball#1213019

Staff note (gir bot) :

Someone approved this submission.
Note: Moved from the Oddball badge along with the 1/2 point it earned there since it's a better fit for this thread.

 
R Parian
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Posts: 267
Location: NW Washington - Zone 8a : 10 to 15 (F)
206
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Recently a design flaw was discovered on the dump trailer when it got a flat tire. The person I had loaned it to went to install the spare tire and found that the sidewall of the spare was significantly worn, to the point of being dangerous to use. This was caused by the spare tire storage location, which is a metal rack on the neck of the gooseneck. The spare tire rested on this rack and was held in place only by gravity, so every bump and turn would cause the tire to shift position enough that over time it wore the tire sidewall rubber thin.  It also wore through the paint of the trailer in the contact points which allowed rust to start to take hold.

I decided this called for a permanent fix to this design flaw.  I used an angle grinder to grind off the rust and flaking paint. I fabricated a spare tire mount bracket by cutting down a store bought spare tire mount to the right length, and cutting a piece of 2"x1" channel steel to the right length, welded them together, painted them, and welded this to the trailer, then wire brushed and painted the remaining exposed steel.

Now the spare tire is securely held in place with two lug nuts making it harder to steal the spare and suspending it about 2" in the air so the rubber is not in contact with anything.
20210807_142629.jpg
Problematic spare tire storage area.
Problematic spare tire storage area.
20210807_142706.jpg
Worn sidewalls of spare tire.
Worn sidewalls of spare tire.
20210807_142740.jpg
Starting materials cut down to proper length.
Starting materials cut down to proper length.
20210807_144946.jpg
Welded together, cut off pieces also in view.
Welded together, cut off pieces also in view.
20210807_145311.jpg
Bottom painted.
Bottom painted.
20210807_145551.jpg
Top painted.
Top painted.
20210809_130502.jpg
Close up of rusty chipping worn area on trailer.
Close up of rusty chipping worn area on trailer.
20210809_130548_05.jpg
Grinding rust and chipped paint off.
Grinding rust and chipped paint off.
20210809_131615.jpg
Ground areas.
Ground areas.
20210809_135149.jpg
Welded fabricated mount to trailer.
Welded fabricated mount to trailer.
20210809_141441.jpg
Painted welds and ground areas.
Painted welds and ground areas.
20210809_170747.jpg
Spare mounted on new mount.
Spare mounted on new mount.
20210809_170813.jpg
Tire no longer in direct contact with anything.
Tire no longer in direct contact with anything.
20210809_170851.jpg
Done.
Done.
Staff note (gir bot) :

Someone approved this submission.
Note: Certified for 1.5 metalworking oddball points

 
R Parian
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Posts: 267
Location: NW Washington - Zone 8a : 10 to 15 (F)
206
cattle goat foraging trees earthworks cooking building solar sheep wood heat
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A neighbor had a gate with unusual integral hinges, but it was missing one of the two hinges so it wasn't able to be used.  They had a need for the gate so I volunteered to fabricate a hinge for it using scrap metal from my boneyard.
20210902_131256.jpg
The one hinge that wasn't missing.
The one hinge that wasn't missing.
20210911_092613.jpg
The location of the missing hinge.
The location of the missing hinge.
20210905_155402.jpg
The materials I started with from the boneyard.
The materials I started with from the boneyard.
20210905_160353.jpg
The section of pipe was too large diameter, so cut a piece out of it.
The section of pipe was too large diameter, so cut a piece out of it.
20210910_172456.jpg
Diameter reduced to proper fit around the gate.
Diameter reduced to proper fit around the gate.
20210910_173427.jpg
Welded the pipe to some channel steel.
Welded the pipe to some channel steel.
20210910_174618.jpg
Welded the channel steel to some flat bar with bold holes drilled in it.
Welded the channel steel to some flat bar with bolt holes drilled in it.
20210910_174940.jpg
New hinge welding done.
New hinge welding done.
20210910_175910.jpg
Paint the hinge.
Paint the hinge.
20210911_092653.jpg
Slide hinge onto gate.
Slide hinge onto gate.
20210911_093053.jpg
Grind paint/rust off the bottom of the gate.
Grind paint/rust off the bottom of the gate.
20210905_160334.jpg
Cut a circle out of flat steel.
Cut a circle out of flat steel.
20210911_095632.jpg
Weld metal circle to bottom of gate to keep gate from being lifted out of the hinge.
Weld metal circle to bottom of gate to keep gate from being lifted out of the hinge.
20210911_095947.jpg
Paint bottom of gate and welds of retaining plate.
Paint bottom of gate and welds of retaining plate.
20210911_100057.jpg
All finished and ready to mount.
All finished and ready to mount.
Staff note (gir bot) :

Mike Barkley approved this submission.
Note: Certified for 1.5 oddball points.

 
gardener
Posts: 1361
Location: Western Kentucky
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Approved BB submission
Had to fix a chainsaw. The plastic worm gear on the oiler stripped out. I couldn't find a replacement, and prefer metal anyway. I didn't have a piece of brass or bronze, so went with 6061-T6 aluminum.
20220101_180252.jpg
Stripped plastic gear. Plastic bad!
Stripped plastic gear. Plastic bad!
20220101_180317.jpg
All chucked up and ready to go.
All chucked up and ready to go.
20220101_181103.jpg
Boring the hole first.
Boring the hole first.
20220101_183215.jpg
Turned the gear part to diameter.
Turned the gear part to diameter.
20220101_190237.jpg
Cut the teeth
Cut the teeth
20220101_190934.jpg
Parting it off
Parting it off
20220101_194127.jpg
Filed two notches and slipped it on the motor shaft.
Filed two notches and slipped it on the motor shaft.
20220101_194953.jpg
It's alive!
It's alive!
Staff note (gir bot) :

Someone approved this submission.
Note: Certified for 2 oddball points!

 
gardener
Posts: 938
Location: Japan, roughly zone 9b - wet and warm climate
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Today I finished making a curved card scraper from an old saw blade.

I generally avoid metalworking because it's really noisy and it terrifies me... but I suited up with my respirator, heavy leather gloves and goggles and had a go at it.

starting metal


removing handle


removing saw teeth


marking up


using disc grinder to remove bulk of waste


Short aside. I have no training in metalworking, but I quickly realized a danger and addressed it with extra caution. When you grind to sever metal, it could theoretically shoot off as a high velocity projectile. Once I realized this (thankfully before it happened) I made sure not to grind all the way through at any point, and snapped off the pieces with my heavy leather gloves or pliers as need be. I also picked up any metal shards and larger fragments with some U magnets and collected them in my metal scrap jar.

cut to shape with grinder


smoothed with a file


For sharpening I watched three different famous youtubers videos, compared the main points, and decided it was easier than I had always assumed because they all left out or did slightly different things with a similar overarching theme.


I don't have a burnisher. I do have a hardened steel screwdriver though. It worked well.


The resultant burr/hook is obvious, I can feel it with my fingertips around the edges. Using it is pretty easy. I get nice shavings. Now I can avoid huge amounts of sanding. I hate sanding even more than metalworking, I guess that's why this project happened!!!


It took me about 3 hours. I'm a newbie. I don't know if I'm talented or not. You tell me!

It's a little bit permie because I upcycled an old saw that had been rusting for ages into something quite useful.

Staff note (gir bot) :

Someone approved this submission.
Note: Certified for 1.5 oddball points

 
pollinator
Posts: 302
Location: Zone 7a
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I built a top-lit updraft gasifier (TLUD) from a metal barrel.
Before


Marking for the top cut and cutting wheel.



Top removed


Before and after cleaning up the edge with a grinding wheel.



Marking for bottom holes.


Drilling holes for that draft. Smaller bit for pilot holes, larger bit. Water to cool off the bits.




Installation of chimney into lid.







Finished
Staff note (gir bot) :

Someone approved this submission.
Note: Certified for 2 metalworking oddball points!

 
The longest recorded flight time of a chicken is 13 seconds. But that was done without this tiny ad:
HARDY FRUIT TREES FOR ORGANIC AND PERMACULTURE
https://permies.com/t/132540/HARDY-FRUIT-TREES-ORGANIC-PERMACULTURE
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