The Shed - Metalwork

A mechanic turns to clocks

16 March 2022

Ken England has been fixing clocks as a hobby in his Whakatane shed since the 90s.
Repairing a clock is not just a case of pulling it to bits, replacing parts then re-assembling, he tells me. “Everything works in sequence and has to be timed.”
He is a member of the New Zealand Horological Institute but was never a clockmaker by trade. What makes Ken “tick” and has given him the necessary clock-repair skills is the engineering know-how already in his background, a knowledge of how to machine parts, manufacture, and silver-solder.

Know the drill

8 December 2021

There are so many varieties of building and engineering materials available these days it is likely that you will need a variety of drill bits in your workshop.
There are always a number of holes required to complete your projects at work, or more importantly those underway in the shed. We are going to cover some of the common products that are readily available from most DIY hardware stores and industrial suppliers, and also some items that you may have to ask for, or even
visit a specialist cutting tool supplier like Trade Tools to find.

Make a handy English wheel

14 September 2021

So it was time to start fabricating my own parts and for that I would need a so-called English wheel machine to mould the tank, guards, seat pan etc. But buying such a machine was “off the budget” as they come with a hefty price tag.
The next option was to build one. With not a lot of plans available, I could see that I’d have some homework to do.

Gasless wire welding is a breeze

25 August 2021

Gasless welding using a flux-cored wire is a MIG welding process that relies on a continuous, tubular wire feed. Gasless wire welding was originally designed as a replacement for stick welding, mostly for use outside where protecting gases could be blown away by the wind and higher productivity was necessary.

It’s a cinch

3 August 2021

Make your life easier with the Tusk Carbide Burr.

Brazing and soldering

28 July 2021

Brazing can be described as the joining of two or more pieces of base metals together using a copper or silver-based filler rod.

Build a sand trolley

3 June 2021

I used a pipe 3200mm long, but it depends on what you have. This is 2400mm along the flat and bent up at the front. The horizontal distance, from the flat to the tip lengthwise, is 340mm. I measured from a square on the pipe, and out 340mm for the bend. The axle is usually 1200mm. I turned a little insert stub axle for putting through the one-inch (25mm) bush in the centre of the wheel and into the axle. You could also turn down the axle to fit. It’s a straight bush because bearings and saltwater don’t mix.

3D Printing

20 May 2021

Here we’re going to use 3D printing to do a modern twist on “lost wax” casting.
It’s a trick that’s more than 5000 years old: make something in wax, bury it in clay or plaster leaving a hole in the shell. Bake the heck out of it to remove the wax and then pour molten metal down the hole. If everything stays together, you get a metal replica of your wax object.

Make your own telescope

7 May 2021

This a project to make a popular Newtonian-design reflector telescope with a Dobsonian mount. The principle of the telescope is to collect light and then magnify the image. The light from a distant object (a star or planet) is gathered by the mirror and brought to a focal point. The eyepiece is used to focus and enlarge the image. By changing the eyepiece, we can increase the magnification and the size of the image. The larger the objective or mirror the more light it can gather and therefore you can use a higher magnification eyepiece.

Metal with pictures

22 April 2021

The basics of engraving are not too difficult and can be mastered with perseverance. However, as with anything, it takes practice to achieve true dexterity and ability. There is nothing more beautiful, timeless, exacting or lasting than a craftsman’s engraving. The best way to begin is to give it a go.

Introducing the new TUSK Ceramic Strip Disc

15 April 2021

The fibres are embedded with coarse grade silicon carbide ensuring aggressive removal of surface applications such as rust, corrosion, epoxy resin, and paint without loading or damaging the metal surface leaving a fine finish.

Man of metal

16 March 2021

Metal is Bill Martel’s passion. He realises his own dreams in metal and those of his customers out of a very large “shed” in Plimmerton, the engine room of his business, Metalmorphic.
During 17 years of high-precision work, he and his team have made all sorts of furniture, balustrades, ornamental light shades, and more, even a 17th-century wrought iron sundial, four metres in diameter, which they “cut up into little pieces” and reassembled to correspond with the southern hemisphere.

Video of the knifemaking workshop of Brent Sandow

24 February 2021

In The Shed magazine Issue 92, we featured master knifemaker Brent Sandow and learned a lot about his knifemaking skills. While we were there, Brent also gave us a guided tour of his well-equipped knifemaking workshop. Be prepared for workshop envy.

Channelling Houdini

10 February 2021

In a sash-windowed meeting room in the upper reaches of the historic Thistle Inn in Wellington, an unusual band of people is preparing for their monthly meeting. Master lockpicker and meeting organiser Derek Robson, aka D.Roc, is assembling an array of locks; dozens of them—mortise locks, pin tumbler locks, tubular locks, various padlocks, combination locks, wafer locks, even a selection of handcuffs, to challenge tonight’s group.

A matter of time

27 January 2021

I purchased all the brass sheet and rounds required, plus a main-spring, brass bolts, and screws of the various sizes needed.
Now where to start on the clock?
I carefully read and followed the order and instructions of the book. If the instructions are not adhered to, many anxious moments and frustrations will follow.

Metalwork