“This Variety Always has Black Bark”

I’m back to writing about my workshop again. Or am I?

Today I wrote about the favor God was showing me. I said it seemed like I couldn’t go to Home Depot without them giving me something for nothing. After I wrote that, I visited the store to get 30 feet of 10/3 power cord for my band saw. The guy who cut the wire made a measuring mistake. I got 31 feet for the price of 30.

Okay, I give up. I surreptitiously returned the last two things they gave me, because I was pretty sure the employees who gave them to me did not have the authority to give things away. This time, I let it go. You can’t give Home Depot back a foot of wire. It was going home with me, or they were going to cut it off and put it in a dumpster. There was no way they were going to go back to the wire area and cut it off. I had to take it.

It was almost as though God were joking with me.

I went to the metal dealer today to get some things I needed. I have a sprayer boom for my golf cart, and I’ve been attaching it to the back of the cart with clamps. That’s no good. I need a support that goes in the cart’s 2″ receiver. I bought three pieces of square tubing to make one.

I also bought several pieces of angle iron in different widths. My Offroad Swag finger brake is a wonderful tool, but in order to make it work, you need accessories. Little pieces of narrow angle iron serve as bottom die adaptors. The press’s bottom die is a huge piece of angle iron which is too wide to work with some things, so you rest small pieces in it to fill up space.

I bought three feet of 1″ steel strip for no good reason at all. I thought I might need some for a plate for the sprayer mount. Screws would go through it to attach it to the boom. I would only need maybe 4 inches for that. I bought three feet because 1″ steel strip is a handy thing to have when you weld. You never know when you’ll find a place where a little strip of steel will save the day.

Scrap is very important. You can’t make anything without scrap unless you drive to the store every time an idea pops into your head. I try to buy more materials, fasteners, paint, glue, and other things than I need, because I know they’ll be useful later.

Yesterday I took some goat wire and stretched it between two shelves on my monster shelf thing. I put it there to prevent long metal objects from falling off the side. I’m using a shelf as a material storage area. The old system of piling it in the corner of the room is no longer in vogue.

Scrap is already piling up on the shelf, making me feel more secure.

I bought 20″ of 2-1/2″ square tube. I made a front end loader support for my Kubota the other day, and it came out great, but it was too short to put the loader as high as I wanted it. The tubing I bought today will become a new support. I could have cut the old support and welded more metal in to make it longer, but I didn’t think about it until I had the new metal, and I don’t know if I trust my welds for a job like that.

When I got home, I cleaned my new steel with window cleaner and paper towels because new steel is always covered with black grime. I deburred the steel using the belt grinder, and I also ground an angle into one of the pieces for the sprayer support so it would project backward from the golf cart when the finished support was in use.

I put 5/8″ holes in the tube that will go into the receiver. There are matching holes in the receiver, and a pin will go through them to hold the support in place. The Silver & Deming bit left huge burrs inside the tubing where I couldn’t hit them with the belt grinder. Enter the Dumore hand grinder.

This is a tool that falls between a Dremel and a die grinder. It’s small enough to use with one hand, but it won’t poop out as badly as a Dremel, and it’s a real industrial tool, so it will last longer than a year. I put a carbide burr on it, reached into the tubing, and ground the burrs out in a hurry.

Nice.

There’s a reason why new Dumores cost hundreds of dollars. Thank God I bought one that was new old stock.

I used a Walter flap wheel to clean up the tubes, and then I used my Harbor Freight MIG to weld them together. It was great. The welds, though imperfect, look better than most professionally done welds. Most pros make ugly welds. Most pros aren’t that good, if you want the truth. It’s a wonder things don’t fall apart and kill people all the time. I was very happy with my work.

The Titanium welder is a joy to use. I don’t know how it will stand the test of time, but for now, I’m thrilled with it. It’s light. It’s easy to use. The Harbor Freight Vulcan welding cart is ergonomically perfect. Zero complaints.

I cleaned the newly made support with a wire brush, and then I sprayed it with black hammer finish Rust-Oleum, using the tried-and-true “hang it from a magnolia tree you don’t mind painting” method. It looks wonderful. There are worse-looking welded products on store shelves across the world.

I’m not totally happy with the tubing I got for the upper part of the support, so I didn’t make that part. I’m going back to the metal place to see if they have something a little wider.

I enjoyed my visit today. The lady who runs the place started talking to me about guns and politics and so on. Of course, she has a carry permit. So nice to live among sane people.

While the paint on the sprayer mount was drying, I started on the front end loader support. I used the dry cut saw to cut one end at a 47-degree angle, which was the biggest angle I could manage with that tool. I then took the plasma cutter and started turning the 2-1/2″ tubing into a C-channel. It has to slip over the tractor’s hydraulic rod, so one side has to be open.

The first time I did this, it took a very long time, because I relied on bad information and didn’t give the plasma cutter enough air. It didn’t cut all the way through the part, so I had to finish the cutting with an angle grinder. This time, I left a few spots that weren’t cut, but severing them only took a couple of minutes.

When I was done cutting one side out of the tubing, I was left with a lot of rough metal on the inside of it. I tried smoothing it with a flap disk, but it wouldn’t really get in there, so I used the Dumore again. It’s terrific. It smoothed and debored everything so a person handling the support can’t get hurt.

I cleaned up the shop and put everything away. The support is waiting for me to come back and weld end plates on it.

I got a great deal done in a very short time. That’s rewarding. So much better than fumbling around and wasting time because I don’t have the right tools or the needed skills.

Welding is a huge blessing. I can make things other people have to buy, really quickly and cheaply. I can customize them. I don’t have to make do with things that aren’t quite right.

I’m planning to build my own welding table. A manufactured table will cost over a thousand dollars, and I just don’t think it’s justified. My milling machine will be here soon, and with it, I’ll be able to make a precision top for the table without paying some company my life savings.

I’ll bet I can build an excellent three foot by two foot table with casters and a fold-out plasma area for $250.

The little Harbor Freight portable table I use now is fantastic for the money, and if you want to weld when you’re away from your shop, it can’t be beat, but it’s flimsy for a main welding table, and it’s small, so it gets crowded.

Maybe if I go to Home Depot tomorrow, they’ll give me a table.

Things are coming together nicely. I almost look forward to spraying the yard.