Category Archives: welding

Welding Robot Takes on a Hot, Dirty, Dangerous Job

They used to say that robots would take over the jobs too dirty or dangerous for humans. That is exactly what [Joel Sullivan] had in mind when he created this welding robot. [Joel] designed the robot for the OSB industry. No, that’s not a new operating system, it’s short for Oriented Strand Board. An engineered lumber, OSB is made of strands (or chips) of wood. It’s similar to plywood but doesn’t require large thin sheets of lumber. To make a panel of OSB, a 5-inch thick matt of wood chips is mixed with glue and compressed down to 5/16″ at …read more

Continue reading

Posted in lumber, oriented strand board, osb, robotics, robots hacks, welder, welding | Leave a comment

Homemade Shop Vise Packs a Hydraulic Punch

It’s a sad day when one of the simplest and generally most reliable tools in the shop – the bench vise – gives up the ghost. With just a pair of beefy castings and a heavy Acme screw, there’s very little to go wrong with a vise, but when it happens, why not take it as an opportunity to make your own? And, why not eschew the screw and go hydraulic instead?

That’s the path [Darek] plotted when his somewhat abused vise reached end-of-life with an apparently catastrophic casting failure. His replacement is completely fabricated from steel bar and channel …read more

Continue reading

Posted in fabrication, hydraulics, metalworking, tool hacks, vise, welding, work holding | Leave a comment

Scooter Hauls Kids With A Little Heavy Metal

Where there’s a will, there’s a way. Similarly, where there’s a paying customer and a well stocked metalworking shop, there will also be a way. That’s about all the backstory you need to understand this latest creation from [Richard Day] of 42Fab. A customer asked him to build something that didn’t exist, and in a few hours he not only fabricated it from scratch but documented the whole thing for our viewing pleasure.

The object in question is a mount that would allow the customer to pull a “Burley Bee” kid trailer behind their electric scooter. The trailer is only …read more

Continue reading

Posted in electric scooter, fabrication, hardware, metalwork, scooter, trailer, transportation hacks, welding | Leave a comment

A CNC Plasma Cutter Table, From The Shop Floor Up

Some projects are simple, some focus on precision and craftsmanship, and some are more of the quick-and-dirty variety. This home-built CNC plasma cutter table seems to follow a “go big or go home” philosophy, and we have to say we’re mighty impressed by the finished product.

For those who follow [Bob]’s “Making Stuff” YouTube channel, this build has been a long time coming. The playlist below has eight videos that cover the entire process from cutting the first tubes of the welded frame to the initial test cuts with the finished machine. [Bob] took great pains to make the frame …read more

Continue reading

Posted in linear slides, LinuxCNC, NEMA 23, plasma cutter, stepper, welding | Leave a comment

Shop-Made Fixture Turns Out Dream Welds

You can tell a lot about a person by the company they keep, and you can tell a lot about a craftsman by the tools and jigs he or she builds. Whether for one-off jobs or long-term use, these ad hoc tools, like this tubing rotator for a welding shop, help deliver results beyond the ordinary.

What we appreciate about [Delrin]’s tool is not how complex it is — with just a motor from an old satellite dish and a couple of scooter wheels, it’s anything but complicated. What we like is that to fabricate some steering links, each of …read more

Continue reading

Posted in jig, rotator, tig, tool hacks, tools, torch, welding | Leave a comment

A Battery-Tab Welder with Real Control Issues

Spot welding should easier than it looks. After all, it’s just a lot of current in a short time through a small space. But it’s the control that can make the difference between consistently high-quality welds and poor performance, or maybe even a fire.

Control is where [WeAreTheWatt]’s next-level battery tab spot welder shines. The fact that there’s not a microwave oven transformer to be seen is a benefit to anyone sheepish about the usual mains-powered spot welders we usually see, even those designed with safety in mind. [WeAreTheWatt] chose to power his spot welder from a high-capacity RC battery …read more

Continue reading

Posted in lipo, microcontroller, spot welder, tool hacks, welder, welding | Leave a comment

So, You’ve Never Made A Spaceframe Before

It is sometimes a surprise in our community of tinkerers, builders, hackers, and makers, to find that there are other communities doing very similar things to us within their own confines, but in isolation to ours. A good example are the modified vehicle crowd. In their world there are some epic build stories and the skills and tools they take for granted would not in any way be unfamiliar to most Hackaday readers.

As part of a discussion about electric vehicles near where this is being written, someone tossed an interesting link from that quarter into the mix; a two-part …read more

Continue reading

Posted in metal fabrication, space frame, spaceframe, transportation hacks, vehicle, welding | Leave a comment

Custom Hydraulic Cylinders from Off-the-Shelf Components

When your project needs power, you might need to turn to hydraulics. There is a lot of mystery about fluid power, but there is also a huge supply chain devoted to getting you the parts you need to power your project. Off-the-shelf components may not fit your application though, in which case it might be handy to know how to build your own custom hydraulic cylinders.

While it’s true that custom cylinder builds are pretty common, it’s still interesting to see the process [MakeItExtreme] used. Starting with an off-the-shelf piston and gland, this double-acting cylinder build is a pretty straightforward …read more

Continue reading

Posted in hydraulics, misc hacks, piston, seal, welding | Leave a comment

Have Chainsaw, Will Travel

What’s the worst thing that could happen if you strapped a chainsaw motor to a tricycle? Turns out the worst that happened to [ThisDustin] and his friends is that it turned out hilariously awesome.

This aptly-named ‘chainsawtrike’ isn’t much in the way of comfort, so a pair of foot pegs had to be welded onto the front forks, along with a mount for the chainsaw motor. The rear axle had to be replaced with 5/8″ keyed stock, trimmed to fit the trike wheel and secured with keyed hubs. [ThisDustin] and crew also needed an intermediate sprocket to act as a …read more

Continue reading

Posted in motor, reduction, transportation hacks, tricycle, welding | Leave a comment