Biking
Recumbent Trike – New Seat & Improvements

I have had the recumbent trike for a few years now. Returning from a ride and cranking up our steep driveway I heard a cracking noise and with each pedal stroke the seat raised up! Pulling over and checking the welds between the rear fork and longitudinal body tube had cracked. So it was time […]

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Metalworking
Path Lights – Powder coating and final assembly

Now that the lights have all of the pieces soldered together and cleaned up, it is time to cut the stems and get everything powder coated. You need to be sure you have calibrated your oven and are sure of the actual temperature vs what is set. Additionally the parts should be placed to the […]

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Metalworking
Path Lights – Making the Roof

The roof is the most complex part of the light. The roof panels are curved and flared towards the bottom. This means the curves are not a simple arc but have a changing curve radius along their length with the shorter radius towards the bottom. If this is not done, then the top won’t come […]

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Metalworking
Path Light Side Panels

The path light side panels are built separately from the roof. Once they are complete they are soldered to the roof. The bottom is the final piece that is added. The side panels are built from pieces of adjustable brass came and brass U came that are soldered together. The thin brass is most easily […]

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3D Printing
Ring Roller Dies for forming a curved V shape

For the Path Light project I needed to make curved corner pieces for the roof. The roof panels are roughly triangular and the corners have a roughly 1/4×1/4 angle of “12 oz” copper to cover the corner. The twist is that the roof panels are not straight but instead somewhat concave giving the roof a […]

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Metalworking
Path Lights Concept

We are on our 4th (or more) generation of path lights for along the front walk and driveway. We live in the country and there is no street lighting. So we need path / landscape lights to provide illumination for safety (of course nothing is level here) and it just looks nice. However the commercial […]

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Metalworking
Low Cost Press Brake

For some upcoming projects I need to neatly bend sheet metals. In the past I had done this for small “one off” items by blaming in a vise or between some pieces of angle iron or using a “tinners pliers” / metal seamer. However now I needed make dozens of bend that are crisp and […]

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Powder Coating
Exterior Light Refinish

Our exterior lights were looking pretty shabby. The original antique / brushed brass was tarnished and dull. 26 years of UV damage had destroyed the original clear coat. There were house paint splatters on them as well. This is one of the smaller lights, by my shop patio. This was also the first major powder […]

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Powder Coating
Powder Coating Startup

I have been interested in doing powder coating for a number of years but this does entailaddtioinal equipment and space (and spousal buy-in). I have been frustrated with conventional finishes (paint, black oxide, etc.) for my metal working projects. Paint takes a long time to dry, requires multiple coats, decent temps to spray and is […]

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Metalworking
Entryway bench

Teal has wanted a bench by the front door to use when putting on shoes. This would be better than sitting on the stairs. Last time we were at Kettle Moraine Hardwoods, the local lumber mill, we came across an interesting Elm slab that was about the right size. So it went in the truck […]

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