The Shed, Author at The Shed

Video of From Rust to rrroarrr – part three

14 April 2025

In my first two articles about the rebuild of a bitser 1952-ish AJS 500 motorcycle, I outlined how I welded a broken cast-iron cooling fin on the motor, checked the magneto ignition and got the head repaired.
I also described what I had learnt about nickel plating (using surplus nickel welding rods and then nickel tape) so that I could make a relatively cheap substitution for chromium, eg on pushrod cover tubes and bolt heads.
Nickel plating was also used to build up a worn kick-starter shaft as a part approach to stopping the kick-start from jamming; I also ground back a couple of teeth on the starter quadrant gear.
My bitser’s gearbox
The gearbox is a Burman CP type, used on many English bikes, with a code G45 L47 stamped on it.
The L in the code refers to the month of assembly, so November.
47 is the year: 1947. So this would have gone into a bike probably in 1948. (My claim to be rebuilding a 1952 AJS looks shakier.)

My shed: Going bush in town

10 April 2025

Many guys like to retreat to a space they have created and feel comfortable in. For some, it’s a shed to tinker in and build things, for others it’s some sort of man cave where they can socialise with their mates.
Gary Were of Stratford, in Taranaki, has gone a step further. The 71-year-old year semi-retired builder and deer hunter has re-created a replica of his favourite bush hut under his urban house.
For 30 years Gary has been deer hunting in the Urewera ranges in the centre of the North Island. It’s an isolated place, where the boys get flown in by Heliseka Helicopter and spend a week each year hunting sika and sometimes red deer.

Welding: Standing to attention – lathe bench build part 2

4 April 2025

I ordered some drawer slides of the appropriate length (350mm) and worked out the width of the slides and thus the width of the drawers. The drawer slides are rated at 45kgs. I couldn’t be sure what weight I would be likely to load but this should suffice. I elected to run with eight drawers and make the second opening in the frame a cabinet to house larger components like the four-jaw chuck. After some fiddling I settled on two drawers each of 75mmx70mmx60mm, and 50mm high, separated by 10mm.
I bought three sheets of cold rolled steel 1mm thick. This is within the limits of the panbrake and I had hoped the material would be stiff enough given that the drawer had to span over 500mm width. I broke the material down into half sheets to make it easier to handle.

The Shed magazine April/May 2025 issue 120 on sale now

30 March 2025

On the road again – new life for old caravans
The allure of a classic caravan can be strong, and many of these gems are being lovingly restored – in fact, Beach Hop even has a prize for the best retro caravan.
In this issue, we showcase three very different caravan restorations—one by a man who owns a company that has been building caravans commercially since the 1950s and is now a household name in caravans and Motorhomes.
The second is a lovingly restored 10-footer that started off a real basket case, and the third, well, friends christened it a turd emoji when they saw the project bought by Marty and Zoe.
Their caravan was destined for their annual pilgrimage to Beach Hop, where thousands gather to show off their super-primped or lovingly restored classic vehicles and caravans

Man who gives a toss

21 March 2025

The incentive for the project came from Dave’s sons, Josh and Andrew. The boys were jumping their bikes and Josh (13) came up with the ultimate idea—throwing their bikes with a trebuchet which they had seen in action on computer games. The boys started with a small trebuchet using stones but it didn’t throw them far so dad got into the act. Dave checked out machines on the internet that were even throwing cars. The world record is a 630-metre throw. He was impressed and thought he would give it a go. He had some Lawsoniana trees he intended to drop so thought now was the time. He finds the Lawson trees were straight and the wood is very flexible.

Welding: Standing to attention

12 March 2025

I moved recently and in the haste to pack I loaded my lathe complete with its stand. The stand, which is really just a couple of sheet-metal cabinets, didn’t really survive the move all that well and it was bent out of shape.
That didn’t really bother me since I have wanted to make a decent stand for the lathe since I got it, and include some drawers for tooling and other bits and pieces. Now that the lathe is in its permanent home I have my chance. This is just a small lathe but it weighs 250kg nonetheless.
I wanted to make something sturdy and solid that would serve to support the lathe without sagging and eliminate any vibrations.

This could be good news for sheddies – but we must be quick!

5 March 2025

Our parliament is currently considering a member’s Bill, drawn by ballot, called the ‘Right to Repair’ Bill. It’s due to go a Select Committee for consideration, and we can make submissions i.e. say what we think of it, before 3 April this year. It’s important because it will make spare parts and information for doing repairs far more readily available and this should slow the rate at which appliances, toys and so on, get sent to landfill.

The great Greek gear train

28 February 2025

Many years ago in a history of technology, I read a passing mention of a strange artefact, a piece of mechanical gearing, that was in the Athens National Archaeological Museum. I didn’t know then, but getting to see this would become an obsession in my life.
The artefact was recovered in 1900 from an ancient Greek galley. This ocean-floor wreck was accidentally discovered by sponge fishermen sheltering from a storm by the tiny island of Antikythera. One of the artefacts later taken from the ship was a corroded block of copper which, after it was cleaned, revealed the vestiges of a complex gear train. This has come to be known as the Antikythera Mechanism.

The Shed King is going to Bonneville, can you help get him there?

26 February 2025

“My name is Dave Alexander, and I am on a mission to set a land speed record of over 420 kph at the iconic Bonneville Salt Flats.
With decades of experience in motorsport dating back to the 1970s, I have had the honour of competing at Bonneville before, where we achieved three records in just one week with my home-built car from New Zealand.
My latest creation is an impressive 7-metre ‘Lakester’, engineered specifically for land-speed racing and powered by a turbocharged Nissan RB30 engine. As a self-employed engineer, fabricator, and welder, I took on the challenge of building this vehicle in my shed with support from a small team of skilled friends.
In February 2025, we successfully completed the build and ran the car on a hub dynamometer, ensuring all systems were calibrated and functions tested. This marked a crucial milestone in our journey. Now, we face the next challenge: packing the car and transporting it across the globe to compete in ‘Bonneville Speedweek’ 2025.

Soldering tips part 2: Getting the job done

21 February 2025

We touched on some simple de-soldering methods in part one of this two-part series.
Just like other workshop tools, there is more than one way to achieve it and with less damage and frustration.
De-soldering involves removing the solder from the joint to either release the component or repair the solder joint. The aim is to do this with minimal damage to either part, but since you can generally replace the component, protecting the PCB is paramount.
SMT (Surface Mount Technology) is a whole other subject, and because of the design and density of the components, different tools are required.
De-solder or rework stations consist of a box controlling a heated tip and a vacuum pump. There are many manufacturers, but I’m only going to discuss some of the ones I’ve had experience with.
While the control box may have shrunk, there is a limit to reducing the handset. The handset consists of a tube to collect the solder and filters to absorb the flux residue. The tips are hollow and reach right through into the collection tube.

A movable bench with fold-away legs

14 February 2025

Before I down-sized my workshop, I had a garage workshop area and plenty of room to have the traditional type of sawhorses or saw stools. Now I have just half of a double-garage which means the stools have to be stored out the back in all weathers.
I was looking at a sheet of 16 mm ply that was 1200 mm square and could see it would make two stools that would fold away flat and could be stored inside. They wouldn’t take up space standing permanently in the garage/workshop and they would need very little room folded away.

Waka building – Tradition goes hi-tech

4 February 2025

Architect, designer, sailor. Add lateral thinker, enthusiast and passionate Kiwi to the mix and you have the CV of a Christchurch man who has made it his mission to put Maori waka back on the water by marrying traditional knowledge with today’s technology.
Quentin Roake’s goal is to find a way to build waka in numbers, recreating the appearance and characteristics of traditional craft in a modern version that is portable, durable, and economical to manufacture.
“The big question is, how do you translate the traditional form of canoe into modern materials? You can’t cut down a big totara tree every time you want to make a canoe,” he says.
Quentin’s quest for a solution involved consultation with tohunga waka (canoe experts), including Hoturoa Barclay-Kerr and Sir Hekenukumaingaiwi (Hector) Busby, and led to Nga Waka Tangata kaupapa, a collaborative project to develop contemporary forms of waka.

Soldering on Part One

31 January 2025

Everyone knows that at some stage you need to blame your tools (after the other excuses have run out), and like most things you can pay a little money or a lot, and sometimes there is little difference in the result … or so it would seem.
The purpose of this article is not to separate you from your hard-earned cash, but to share a few tricks and provide some information to make an informed choice when buying equipment.
Everyone knows that the best soldering iron is some large lump of material that you throw into the fire until it is red hot and then apply to the job and hope that some of the exploding material fuses the bits together.
That might work for joining two bits of metal together but it is not going to work for electronics.
Soldering electronics is not only mechanical bonding, but also making an electrically conductive joint. The solder used has a particular temperature range and too hot will ‘cook’ the joint and make it porous, while too cold means it sticks to one or other part but doesn’t bond.

Video of from Rust to Rrroarrr Part two

28 January 2025

From Rust to Rrroarrr Part Two
As featured in The Shed magazine, February/March 2025 issue 119
A six-part magazine series on the restoration of a 1952 AJS Motorbike
PART TWO – Metal plating:
The secrets of successful nickel plating
In part one of this restoration series, Peter described how he started rebuilding, as cheaply as possible, an old bitser AJS 500 motorbike, and discussed the start of his nickel-plating tasks.
For this Rust to Rrroarr project, he has decided on a nickel-plating finish instead of chromium for his AJS. In this part two of the six-part series, Peter describes his nickel-plating process

The Shed magazine February/March 2025 issue 119 on sale now

26 January 2025

The Shed