The Shed - Welding

Going glamping

23 November 2023

What do you do if you want a caravan but drive a Mini? You make one to fit. That’s just what Michael Wolfe of New Plymouth did – turning out a real dinky little teardrop-shaped caravan that matches his 2004 Cooper S and has all the mod cons for a decent holiday.
Michael saw pictures of little campers on the net and decided that was what he wanted – a cross between a caravan and a tent.
“I got some ideas from little caravans online and decided to go a bit more high-tech,” he says.
He built it to have the same lines, wheels and colour as his car and it looks just the part.
“I never really planned it in detail. I sketched it out originally and a lot of the construction I worked out as I went along.”

Up the wall

18 October 2023

A friend loves gardening and has always wanted a vertical garden or ‘living wall’. She has been pestering me to build one ever since I started doing the welding articles for The Shed. I looked at a few and developed a simple concept that is simply an angle iron frame with a wire lattice.
I measured the wall it was to fit on and arrived at a final size of 1m x 1.6m. I
happened to have that on hand in 3mm angle iron. The vertical garden needs
to be offset to the wall to allow for air circulation and watering. I decided to offset it
by 60mm so that required 100mm feet.

Steely eye

2 August 2023

One glance around Allan O’Loughlin’s garden and it’s clear that this is the home of someone with a vivid imagination and the creative skills to bring it to life.
Allan, a fitter-welder and self-taught sculptor, uses the skills learnt in his trade to create works of art in steel. More than 60 of them are scattered around the 9000 square metre property he shares with his partner, Andrea, in Mandeville, 25km north of Christchurch.
Unlike most artists working in the medium, Allan doesn’t construct his sculptures by bolting or welding solid metal shapes together, but relies on the properties of molten steel to mould and fuse his forms.
His initial frameworks are simple structures made out of wire and builders’ reinforcing rods which he curves into shape using heat and a home-built metal former.

Raising the bar

31 May 2023

I have wanted to make an elevating bar stool for some time. They are a relatively simple design – four legs attached to a nut through which an acme thread runs, raising and lowering the seat.
However, attaching the legs to the nut is problematic. The nut is usually a fairly large piece of steel, in this case it’s 38mm diameter, and even with the hole and threads cut it still has a wall thickness of nearly 10mm. The legs on the other hand have a wall thickness of only 2mm. That size differential makes using MIG welding difficult. It can be done of course but it isn’t quite as straightforward as usual.
I felt it was ideally suited to TIG welding and as I hadn’t tried TIG before I thought this might be a good opportunity to get some experience.

This offroader project is a beaut

23 February 2023

Over the last couple of years, my son Kurt and I have built a few basic go-karts which not only gave him a taste of very basic engineering, but also allowed us to pile up valuable hours of quality time working together in the shed. This new project had a bit of a twist to it as, this time, my son was the chief designer and engineer and I was relegated to labourer. Like all the previous projects, he let me fund it.

Build a portable barbeque

24 August 2022

At home, I have a big barbecue in the backyard and a little barbecue upstairs on the balcony that I use when there are just two of us. This hibachi or portable barbecue would be ideal for just two although the grill rack is big enough for four or five steaks or chops and sausages. It can be made with scrap mild steel and a piece of cut pipe. You will find scrap bins at your local engineering works. Most pieces of metal under a metre seem to go in there. You could ask and many companies would be happy to help out, perhaps for a couple of beers.

Welding with LPG

16 August 2022

Long before MIG welders or fancy plasmas came onto the scene, the art of welding, cutting, and brazing was to work with gas. The hire or exchange cylinders used by sheddies invariably were oxy/acetylene as this was one of the most common processes for welding, cutting, or brazing.
But there is an alternative–liquefied petroleum gas (LPG) and oxygen. This combination can be used for heating, bending, brazing, soldering, silver soldering, and flame gouging to name just a few applications.

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.

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.

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.

Burning bright

15 December 2020

Making a brazier is one of those things that I am sure every sheddie has at the back of their minds to create one day. It’s just that, as we know, “one day” takes its time arriving.
I have to admit that I am no exception to that rule. Even when the component parts presented themselves to me it took a while before I found the time to put into the project. Six truck brake drums that had outlived their useful life were the starting point, donated by the owner of a fleet who only asked that one of the braziers be made for him.

Pleasant Point Railway photo gallery

17 September 2020

We visited and wrote about the impressive Pleasant Point Railway & Historical Society in South Canterbury, in The Shed September/October 2020 Issue 92.
Sadly, we just couldn’t squeeze in all the great photos we shot for the article into the magazine. As you will now see, these unpublished photographs are just too good to leave sitting on our hard drive so we felt we just had to share them with readers.
Enjoy.

Shed 92 on sale across Australia today

16 September 2020

For all our Australian readers the wait is over to grab the latest issue of the magazine. The September/October, Issue 92, hits the shops all across the country from today 17 September.

Is it a beer keg? No, it’s a hangi

8 September 2020

It’s not every day that you come across a blindingly brilliant and deceptively simple use for a piece of gear that you just knew would come in handy one day.
When sheddie Stan Scott showed me his prototype portable beer keg hangi, I knew it was something that the world needed right now… like world peace.

Video of the weird and wonderful world of Andrew Hall

26 August 2020

A visit to Andrew Hall’s shed — a single garage in suburban Henderson, West Auckland — is a portal into another dimension. In this realm, a sense of humour is essential.
For the past two decades, Andrew has been working full time at turning society’s cast-offs into three-dimensional cartoon gargoyles, aliens, monsters, and effigies of mirth.

Welding