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Puget Dude’s creations and fabrications (Random project thread.)

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PugetDude

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Since today is Veterans Day, it seems appropriate to start with the license plate flag I just finished up. Used Connecticut plates for the blue since they are The Constitution State. Arizona for the red since we’re living here now. Wanted to use the Oklahoma Bicentennial plates but they were too yellow. AC4F927C-1724-45BA-B707-1CD15AFC3DEC.jpegI gave them an overnight soak in Simple Green to see if I could clean them up but that turned out to be a real bad idea…6B4F4A01-FCC1-40A2-9D0B-092443E93AE3.jpegThe entire paint layer peeled off in one piece! So I shifted to Illinois Land of Lincoln… found a eBay listing for a 35-piece lot. 8B0BDD64-5387-48AB-96CC-D2462F39E485.jpegThe dark red letters matched the Arizona plates really well but there was too much blue on the bottom half to use as the white stripes. Ended up hitting them with a thin coat of gloss white and then using a Q-tip dipped in paint thinner to clean the white off the dark red letters.
681011AC-3931-4CF1-A25B-2C4D5AD5C3E2.jpegThe backing is just 1x cedar fence boards from HD. I used them because they are lightweight and should be able to handle limited weather exposure. Hit them with a coat of White primer and then painted the color where appropriate to eliminate the white shining through between the plates. 807E59A9-B9B2-479E-A639-3468E0516252.jpegAll I could find were dog eared boards so I trimmed them to 71” to square them up.
 
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PugetDude

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I started collecting the license plates for this project a couple of years ago; knew I was going to have to cut them down.
Always wanted an Original Beverly Shear, but was never able to find a good used one (in any condition, actually) so I popped for the Eastwood knockoff. Have to say I am pretty impressed with it, cut perfectly right out of the box. Needed a stand, so I copied an original Beverly stand (scaled from photos I found online) for it to sit on.
It’s built out of 3-1/2” x 3-1/2” x 1/4” angle, and 1” and 1/2” Schedule 80 pipe. Spent more time grinding my ugly welds than I did fabricating. It’s really been a great addition to the shop.D3FC9D08-9261-46FF-959B-58CD7B284DFA.jpeg4028AC66-760C-4D6C-B328-9CC2C594E6C5.jpeg
 
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PugetDude

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Found a picture of the garage before I started filling it up. This house actually has 5 garage spaces- my side is the 3- car, my wife has the 2-car that’s perpendicular to this one. She’s the one that wanted more garage/shop space; she was tired of me bitching about working around our cars in a (barely) two car garage. Originally this was all one space, but I put up a wall to keep my shop mess out of her side (and so I could add A/C to the shop side someday)84BB80A4-2C1F-4C42-94D7-94951EA7D097.jpeg
 
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LXCam

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Quit holding back, I know you got more exquisite abominations to share. I’ve seen the evidence.

😎
 

Jayman17

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Pugetdude it’s good to be able to see the space you work out of. Nice flag project and I like the locker/hardware cabinet worktable you made. Shop looks pretty spacious.

Jay
 
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PugetDude

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Pugetdude it’s good to be able to see the space you work out of. Nice flag project and I like the locker/hardware cabinet worktable you made. Shop looks pretty spacious.

Jay
Jay, the lockers were a fun project but I failed on the mobility issue. Used 13” diameter run flat tires (same diameter as the depth of the HF storage boxes, that way I could still open the locker doors). They worked fine until I loaded it up, compressed overnight too much to even turn.

It’s essentially turned into a work island.
They started out as 6’ high x 6’ wide 8-door double stacked gym lockers.
First order of business was to cut them into 2 banks of 4, single high.
 
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PugetDude

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When I cut the lockers apart I had to let the 1” center frame go with either the top or the bottom. When I reassembled the former uppers and lowers back to back, I had to add a 1x1 tubing frame to replace the missing frame section. It was a simple job, but I had to shim the door gaps so the doors would operate properly when everything was welded in place- no way to make any adjustments. Tacked it all together and then fabricated a base frame out of some old 1-1/4” bed rails for the lockers to ride on. I had some 2x2 angle but I was trying to keep the finished height as low as possible since the lockers were 36” tall to start with. 37155F75-AD1F-4402-B799-1660F1D97218.jpeg5F4B07BF-213B-4945-8421-99B0754735E1.jpeg
 
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PugetDude

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Once I had the lockers tacked together I started on the SOJ-inspired rack for the flip top HF storage bins. Since I am a scrounger and like to use what I can dig oout of my steel stash instead of driving across town for new stuff, this was built from 1/2” x 1-1/2”rectangular tubing I had left over from an old architectural iron project a few years ago. Couldn’t use more than 1/2 thick and stay within the 36” overall width with the HF cases.
I had some 1/2 plate about 8” wide in the bin so I used that for the axle mounts. The axles are just 5/8” bolts welded to the plate; no room on the inside for the bolt heads with the storage bins. 9C94A13E-6434-4F8C-AD60-E12F554B32C1.jpeg
 
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PugetDude

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After adding a few gussets/tie down holes for the top, the steel work was complete. Time to roll it outside and sand off the surface rust and give it a coat of paint.343EA058-B957-47AD-B8B7-BE0F82CE3EB4.jpeg62CF80F6-78A4-4025-8F9A-6CB925D1E372.jpegTwo coats of Rustoleum Safety Yellow. Put a splash of Penetrol in the paint to help it flow out better. Used a foam roller and a cheapie disposable paint brush where the roller didn’t go. Touch up was with an aerosol can of Safety Yellow. In hindsight I would have added a bit of hardener to the paint; but after two years I’m pretty sure it’s finally dry. (Did I mention how much I hate Rustoleum?)
 
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PugetDude

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In the homestretch now, ready to move on to the HF storage bins. I had picked up a bunch of 2x2x3/16” aluminum angle shorts at my metal supplier a while back, these were perfect for the simple supports I had in mind. 86C27A3A-917E-4A6F-A870-E74C1D02CE74.jpegA3570E05-053E-4949-A242-F22E7EEC2E8D.jpegFinal step was adding the top. I found a 36x80solid core wood door at a building materials close out place near the Phoenix Airport. A piece of 1/8”Masonite hardboard was added to protect the top. It’s easily replaceable if It gets too banged up. Cut it to rough size, shot a few brad nails around the perimeter; after a quick trip around the top with a flush trim bit in the router this thing was ready to roll…. Until it didn’t.
 

Jayman17

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Nice job on that, too bad the wheels didn’t work for you. I think your plan for mobility was a good idea with that trailer jack in front.
I just set up a workbench using the exact same thing for the top, a solid core door and 1/8” Masonite.

Jay
 
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PugetDude

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Safety warning… don’t cut aluminum angle too quickly with a miter saw. If it binds, it yanks the angle over the fence …and it really hurts if your finger ends up in between. It jerked so hard it bent the arbor and broke the fence on my backup 30 year old Ryobi miter saw, I was really lucky it didn’t drag my hand into the blade.3A5F17A8-3DA8-4B48-9D79-DDB5DF307F35.jpegStill dealing with a mass of scar tissue under the finger tip almost 2 years later.
 
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PugetDude

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Gotta say I am loving the HF bins. Need to get out the label maker and get them labeled properly now that that are full. I used a strip of painters tape to identify the content as I was filling them up. Why so many Teks screws? This house is all steel framing, it was built in 2005 during the building boom by a commercial contractor as his personal residence. Steel Framing, 5/8" commercial Firecode drywall. Only wood is one 50' gluelam beam spanning the back patio. 9A6AB6D6-9468-44D9-83B2-B6F36C5B2F98.jpeg
 
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PugetDude

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With the almost-rolling workbench done for now it was time to move on to another project- a memorial bench for my Father in Law for our side yard landscaping project. First step was the base for the legs.798317EB-4F22-4977-B45D-451A199DF7B3.jpegWe were working on a large remodel in our big vacant gravel side yard, wanted a fitting memorial for him, and a place for my wife to visit him here- so we sprinkeld a few of his ashes around the tree we planted behind this bench, the rest are interred with my MIL at the National Cemetery in CaveCreek, AZ.4CC6E79B-361D-449D-BD9E-3A0EC9952776.jpeg157EB1BA-2DCE-4902-8AE4-17BABD58A8EE.jpeg
 
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Monza Harry

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Damn Nice there PD! You sure sucked up some Serious Bonus Points with the Boss Lady there didn't you? [did you need forgiveness or are you planning on asking for permission, I'm thinking a new tool purchase ;)] I wouldn't mind a peek at how you did that lower plaque, as I'm sure others wouldn't mind either. Thanx for sharing, VERY classy/fitting result! Harry
 
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PugetDude

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Damn Nice there PD! You sure sucked up some Serious Bonus Points with the Boss Lady there didn't you? [did you need forgiveness or are you planning on asking for permission, I'm thinking a new tool purchase ;)] I wouldn't mind a peek at how you did that lower plaque, as I'm sure others wouldn't mind either. Thanx for sharing, VERY classy/fitting result! Harry
Thanks, Harry.
First photos in this build are the curved ends of the 1x1 tubing that made up the top and bottom pieces that were welded to the 1x3 crossbar to make the mounting boss for the plaque. Took a bit of grinding and flap wheel work to smooth it all out. My welding may be bit rough but I do grind better than most. :D
The plaque is a piece of 1/8” aluminum plate that my good friend Ron had engraved at a local trophy shop. He and Tom were very close, they had a special bond ( both career Army although a generation apart.) I bandsawed it into the Army dogtag shape and cleaned up the cut line on the 2x72 belt sander after it was engraved. Block sanded to even the luster; shot it with a coat of clear and pop-riveted it into place.34D7B988-597C-4042-97B4-0AC89EACBBDF.jpeg387CF908-3240-4E9A-89A3-4EAC0FEAB5D7.jpeg1F85909F-FD28-4823-8252-28CEDDC6642B.jpeg
 

Jayman17

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Wow, nice bench, I’ll bet your wife loved it. I might steal that technique for making a curved end on a piece of tube. That was slick.

Jay
 

Bears Fan

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Damn Scott, You have a great eye! these are all awesome projects! What else do you have hiding in there? That is one awesome view out of your garage door :cool:
 

Monza Harry

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Thanks, guys. Trying to figure out how to integrate my mother-in-law into this bench, might have to build another one. They were married 65 years, died 10 weeks apart. Any ideas?
PugetDude, Might I suggest a backrest with a recessed area with a picture of them, He in uniform. her in whatever pic you have (?) that is available to you. Even tattered would fit as that is the way the vets' pictures of their loved ones ended up carried everywhere they went. Take the photo and do an "Acryliazation(sp?) from "The Art of Custom Painting" from the early '70's showed this technique [Metalflake (IIRC) ad from a magazine that is when I bought my airbrush from them]. You basically clear coat over a picture and then rub/wash the paper off of the back and set it into the clear coat of the finished paint project. If you bought a couple of copies of the picture you decide on another "Dog Tag" with a raised edge set the picture in and then some epoxy casting resin and you have another plaque. Maybe with another engraving under the photo, with some meaningful words +/-?
And I was hoping for some neat tips for shop built engraving with respect to the plaque, I'm not sure if there are any trophy shops left in my area, there is online I suppose. Thanx Again PD! Harry
 
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PugetDude

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Since these are in no particular order, here’s the address marker I made for the house. We’re in a small gated community of 45 homes on ~acre lots; most of the neighbors have their addresses on boulders or flagstone. I’m more of a metal guy, so I decided to integrate both.

The previous owner had a nice thick piece of flagstone and some ceramic tile numbers she was going to use for her address marker. I liked the flagstone, so I kept it and sent the tiles to a local thrift shop.

Wanted something that reflected the mining heritage of the Superstition Mountains and incorporate the rusted iron design elements we already had going on the property.
Had a bunch of 3/8” rebar and 1x1 tubing left over from the trellises I built for the courtyard and golf course so I used that. First step was to build a rebar cage for the Palo Verde stone we already had in the landscape drainage. C277DCE0-2655-4525-8650-2BC6888A097C.jpegAfter the cage was complete I scrounged up enough sheet metal to built the bulwarks. Outside wall were cut from 16 gage steel purlin stock, the inside walls were cut out of a couple of old 2’ recessed light troffers. (did mention I am a bit of a scrounger, didn’t I?)The tops were new 20 gauge that were just hand bent and tacked into place. After A couple of hundred tack welds the corners were ground smooth and blended. EAEA32DB-B00E-4972-A6D9-1B122730AC4E.jpegNext step was to hit all the flats with a flap wheel to remove all the paint and prepare for the patina.
Best way I have found to put an instant rust patina on steel is to spray it with a mixture of vinegar, salt, and hydrogen peroxide. It will foam up as it works, don’t try to wipe it off- just let it go, it will disappear as it ages. E314E186-D168-4741-94F9-3D79DCB1D2E9.jpegFormed and poured a little pad to bolt this to. Used it as an opportunity to get rid of more pieces of scrap rebar, etc.-tacked together a little reinforcing cage, then poured three bags of ready mix. Added a bottle of buff concrete color let the slab blend into the landscape gravel. 39614B48-2889-4329-8932-D8328AE1ACE6.jpegReady to install the marker, just put in a couple of Tapcons to keep in in place, then filled the rebar cage with 4”+ Palo Verde stone. Top bolts on with four 1/4” bolts, nuts were welded into the frame and ground flush during fabrication. F188D794-A4C4-4047-A213-D4848A13908F.jpegI actually tried to copper plate the steel numbers with copper sulfate using instructions I found online but it didn’t really work. I wanted them to weather out naturally to a copper verdigris finish, but that might be a project for a later date. The numbers were bandsawed out of 3/16” plate with 5/16” bolts welded to the back as stand offs. They’re just friction fit into 5/16” holes in the flagstone so I can just pop them out and get them plated if I decide to go that route.
 
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royce

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fairbanks ak
Didn’t take many pictures of the weld-up, but here’s the completed bench. Used 1-1/4” pipe for the front side, will be more comfortable to sit on with the rolled edge. 9ADF8BC5-6A2F-4A88-95BE-584B039E2118.jpegBCA7C092-FCD2-4C99-A245-E226B4262E58.jpegC53D10D4-0952-4E5F-B52A-48B546B6FC97.jpegActually built this as a surprise for my wife, she was gone for a long weekend visiting her daughter and grandkids.
Beautiful design, color, and execution
well done
 

royce

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Since these are in no particular order, here’s the address marker I made for the house. We’re in a small gated community of 45 homes on ~acre lots; most of the neighbors have their addresses on boulders or flagstone. I’m more of a metal guy, so I decided to integrate both.

The previous owner had a nice thick piece of flagstone and some ceramic tile numbers she was going to use for her address marker. I liked the flagstone, so I kept it and sent the tiles to a local thrift shop.

Wanted something that reflected the mining heritage of the Superstition Mountains and incorporate the rusted iron design elements we already had going on the property.
Had a bunch of 3/8” rebar and 1x1 tubing left over from the trellises I built for the courtyard and golf course so I used that. First step was to build a rebar cage for the Palo Verde stone we already had in the landscape drainage. C277DCE0-2655-4525-8650-2BC6888A097C.jpegAfter the cage was complete I scrounged up enough sheet metal to built the bulwarks. Outside wall were cut from 16 gage steel purlin stock, the inside walls were cut out of a couple of old 2’ recessed light troffers. (did mention I am a bit of a scrounger, didn’t I?)The tops were new 20 gauge that were just hand bent and tacked into place. After A couple of hundred tack welds the corners were ground smooth and blended. EAEA32DB-B00E-4972-A6D9-1B122730AC4E.jpegNext step was to hit all the flats with a flap wheel to remove all the paint and prepare for the patina.
Best way I have found to put an instant rust patina on steel is to spray it with a mixture of vinegar, salt, and hydrogen peroxide. It will foam up as it works, don’t try to wipe it off- just let it go, it will disappear as it ages. E314E186-D168-4741-94F9-3D79DCB1D2E9.jpegFormed and poured a little pad to bolt this to. Used it as an opportunity to get rid of more pieces of scrap rebar, etc.-tacked together a little reinforcing cage, then poured three bags of ready mix. Added a bottle of buff concrete color let the slab blend into the landscape gravel. 39614B48-2889-4329-8932-D8328AE1ACE6.jpegReady to install the marker, just put in a couple of Tapcons to keep in in place, then filled the rebar cage with 4”+ Palo Verde stone. Top bolts on with four 1/4” bolts, nuts were welded into the frame and ground flush during fabrication. F188D794-A4C4-4047-A213-D4848A13908F.jpegI actually tried to copper plate the steel numbers with copper sulfate using instructions I found online but it didn’t really work. I wanted them to weather out naturally to a copper verdigris finish, but that might be a project for a later date. The numbers were bandsawed out of 3/16” plate with 1/4” bolts welded to the back as stand offs. They’re just friction fit into 1/4” holes in the flagstone so I can just pop them out and get them plated if I decide to go that route.
Rustic, simple beauty, so pleasing to the eye.
Well done
 
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