Project #2, Welded Base for Sculpture, d.fisher

This is a new sculpture that I am currently working on. It is very experimental to say the least. The first photo is of a smaller model that I made in the past from silver soldered 3/32 tool steel rod. The current structure that I am welding is made from 1/2" mild steel. I will be posting pictures of the jigs that go along with this project. There is a good chance that I will be making multiples of this same piece, so having the templates ready to go will make it easy to duplicate in almost exact standards.

Ignore the top part of this piece, I am just focusing on the steel stringers for this project.
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I am doing all of the layout and bending on a jig made from mdf (medium density fiberboard) and angle brackets. I layout the drawing on the board to begin with and then attach the angle iron at strategic points. In this case, the first pieces to go on need to have a slight bend. I do this right on the jig to ensure each one is almost identical.

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In order to do the hot bending on the jig and not set the place on fire at the same time, I elevate the 1/2" round bar with square spacers. In addition, I add scrap steel sheet (1/8") in and around the area where the torch is being used. By keeping the torch parallel with the surface (horizontal), most of the heat is deflected away from the mdf. You can see some evidence of the torch, but it is very minor, more or less just a bit toasted.:)


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To make the horizontal supports, which are just squares, I experimented with this jig. I cut scrap plywood to the inner dimension of the square needed. I then mitered away the corners where the welding takes place for two reasons, one is obviously the heat issue, and two, for clearance while welding. (By the way, I am only doing mig welding, I do not have a tig welder yet, saving my pennies!).

I am saving these blanks, because I foresee making this same exact structure in the upcoming weeks. All together for this piece, there are 5 squares, and I was able to mindlessly clamp the parts and make the finished product in no time at all, and no worrying about square-ness..

The pieces were tacked, and then taken off the form and finish welded.

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Here's a detail shot of one of the finished squares. I didn't weld inside of the corner, I am still on the fence about that. I like the cleanliness of the joint as it is, but I am worried about it's strength. More or less, the joint is welded on 3 of the four sides. If anybody can help with this, I'd appreciate some feedback. Thanks in advance!

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Once all of the inner supports were made, it was time to tack them on. This was a little complicated, but here's how I decided to go about things. I needed to weld the squares at an angle identical to the bend in the vertical pieces (the long rods clamped to the jig). The angle is due to another bend that needs to be made once the pieces are in place.

I created an angled clamping block out of plywood and two strips of birch. One side rested flat on the jig, and the other was used to stabilize and clamp the square at the proper angle. It all makes sense in the upcoming posts, I promise.

Notice I have also added locator blocks on the jig to clamp the squares at the bottom. These are permanently fixed to the jig with glue and a nail gun.

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I must have been excited about this actually working, because I failed to take photos of the final two uprights being welded, and the final piece all tacked up on the jig.

So, the final two squares were welded at 90 degrees, nothing special. Once off of the jig, I set up to make the other bends. This will in turn make the angled squares and the 90 degree squares parallel. I used an oxy acetylene with a rosebud torch for quick heating. Both sided were heated and the bend was made slowly. I checked the distance between the squares as I was going, once the piece was parallel, I knew I was at the correct angle.

The material support was used as a guide. I would lower it slightly, heat and bend till it made contact, and check my measurements. The bend was taking place right at the edge of the table.

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Here's how the piece sits at the moment. Hopefully I will get some welding time later today. I still need to add the other two vertical pieces. So to duplicate the same size, location of bends and all, I used the original jig again. Only this time, I added some temporary bars to keep them together while bending. I will take the bars off as soon as everything is tacked together.

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Originally Posted by d.fisher

This is a new sculpture that I am currently working on. It is very experimental to say the least. The first photo is of a smaller model that I made in the past from silver soldered 3/32 tool steel rod. The current structure that I am welding is made from 1/2" mild steel. I will be posting pictures of the jigs that go along with this project. There is a good chance that I will be making multiples of this same piece, so having the templates ready to go will make it easy to duplicate in almost exact standards.

Ignore the top part of this piece, I am just focusing on the steel stringers for this project.
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nice sculpture, looks like a lot of small welding!

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Originally Posted by charger891

nice sculpture, looks like a lot of small welding!

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Thanks! I have a background in jewelry and silversmithing, so I like stuff on the macro scale. It makes for quick welding too, cut down on the surface area!!

Looks good D. It looks like you are seeting up to mass produce. I wish you well in selling them...

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Originally Posted by d.fisher

Here's a detail shot of one of the finished squares. I didn't weld inside of the corner, I am still on the fence about that. I like the cleanliness of the joint as it is, but I am worried about it's strength. More or less, the joint is welded on 3 of the four sides. If anybody can help with this, I'd appreciate some feedback. Thanks in advance!

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All depends what kind of weight your putting on it and where, if its weight only on top all the stress will be on the legs and your squares just act as a support

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Originally Posted by charger891

All depends what kind of weight your putting on it and where, if its weight only on top all the stress will be on the legs and your squares just act as a support

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Ok good, thats sort of what I figured, there's going to be about 300 lbs on top, static weight, dead center. Does that change your opinion? It's not the end of the world to finish weld, but I'd rather keep it clean and sharp in the corners.

300 lbs on top, i wouldn`t wory about finishing the welds, the weight will then only be on the upright legs and the pressure on the squares would only be the amount to hold them from spreading out.

Ok great, thanks charger, It's always nice to have feedback like this from experienced welders. I don't have any formal training in welding or certifications, just time in the saddle and some logic here and there.

I need to start fabricating the top, where the second part of the sculpture will sit. I have some 3/8" x 4" wide plate that is laying around and will work well. I need access to the middle, so the open part in the center will work out great. Since each joint is a butt connection, I am chamfering most of the area to get a good sunken weld. I don't want to weld on the otherside, because that may be visible, and I don't want to do a lot of finishing. I feel a little lazy today.

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I started adding clamps everywhere I could. I don't want this to warp. If I can minimize this in another way, please let me know.
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So I tacked everything in and ran some beads. It's cooling at the moment, and I cranked down on the clamps pretty good. There doesn't seem to be any movement or warping yet.

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I wanted to drill holes in the top plate to help locate the uprights and provide a cleaner way to weld the parts together. That didn't work out so well on this attempt.

Here I am at big Claus, getting ready to drill the holes.
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Big Claus handled the 1/2' holes no problem.
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My problem was me. I, for some unknown reason, pulled a number out of my head and thought that was where the rods would line up. I was off by about 3/4 of an inch. Really bad. I think we'll leave those holes in there, and just keep moving on. At least they are uniformly drilled on the piece right?

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Originally Posted by Powertig

Looks good D. It looks like you are seeting up to mass produce. I wish you well in selling them...

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Thanks Powertig. I'm not so much going mass production, I just need about 5 or six that are darn near identical. This one is turning out to be a learning experience. I hope they sell too! I really enjoy what I do, but money is always nice too!

I worked my way up the piece. Sometimes having to make spacer blocks to keep the bars parallel. Overall, it worked out. Not as seamlessly as I had dreamed of last night, but hey I can't complain. So here's the final shot of the structure all tacked up and ready for some finish welding. I think I'll save that for another day. I've got a few other projects burning that need some attention too!

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Man your cruising along! looks good so far!