tag:blogger.com,1999:blog-58525057654280630062024-03-13T01:01:23.964-04:00WardWorksChronicling my creative endeavors - home projects, props, wood working, short stories, articles, costumes, graphics, movie reviews, 3d models, and videos.WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.comBlogger283125tag:blogger.com,1999:blog-5852505765428063006.post-70470126395943846572023-12-01T02:00:00.124-05:002023-12-01T02:00:00.146-05:00Roller Chain Bracelet<span face=""arial" , "helvetica" , sans-serif"><b>Chain Bracelet</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6rL7Z-k2sa-UISs7hh4-tqTSqR1O_T6tKGI8kI4ChLu-AMm8W3eAkOSlw2Yt1_b4G52iC4dcfhhuhcrc8sMWmIxBL6O1WCOmrbbWd2BUuH83wcxSKur0foPEjJJ31bF4BL69yIzIzorgtAQUd_SHmeGNhjWTOD-mw2Q5PebS8_1c4lvOIAW1yFlzhDJA/s640/IMG_4955.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6rL7Z-k2sa-UISs7hh4-tqTSqR1O_T6tKGI8kI4ChLu-AMm8W3eAkOSlw2Yt1_b4G52iC4dcfhhuhcrc8sMWmIxBL6O1WCOmrbbWd2BUuH83wcxSKur0foPEjJJ31bF4BL69yIzIzorgtAQUd_SHmeGNhjWTOD-mw2Q5PebS8_1c4lvOIAW1yFlzhDJA/s16000/IMG_4955.jpg" /></a><br />I see any kind of chain and I automatically think bracelet or necklace.<br />
<br />
<a name='more'></a>I wanted a simple and quick project and this was it. It also looks cool. I like the industrial look.<br />
<br />
<b>Purchase List (paid links):</b><br />
<div>
<a href="https://www.amazon.com/Drive-Chain-Roller-Feet-Motorcycle/dp/B074MKKWTD/ref=sr_1_4?keywords=%2340+roller+chain&qid=1551794799&s=automotive&sr=1-4" target="_blank">#40 roller chain</a> - $10</div><div><a href="https://www.amazon.com/Aluminum-Armature-Bendable-Beading-Skeleton/dp/B086QXXFXD/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=96e2e3a2062444c47ff0601fc7fb9638&camp=1789&creative=9325" target="_blank">14 gauge wire</a> - $15<br /></div><div></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSk_cFXTHAPXhL7h6f5aoLXAQJlq4OGycu-m4b00vHJvZWh-RdDom0hUf-05KWNPocuEWLTiuO8Hf0XtcxNuLviMcxOJZM2zLT4KGHaFL6ALtupSpNPeG817mi9xCOvk0V6tigaf-Av2JcNr0LoZ0XVnGiR3-4bPQamLw3MqjplhDQBdxrE9omqfQCJ2I/s640/IMG_4946.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSk_cFXTHAPXhL7h6f5aoLXAQJlq4OGycu-m4b00vHJvZWh-RdDom0hUf-05KWNPocuEWLTiuO8Hf0XtcxNuLviMcxOJZM2zLT4KGHaFL6ALtupSpNPeG817mi9xCOvk0V6tigaf-Av2JcNr0LoZ0XVnGiR3-4bPQamLw3MqjplhDQBdxrE9omqfQCJ2I/s16000/IMG_4946.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">#40 chain, #40 chain, #25 chain<br /></td></tr></tbody></table><div>
</div>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaAab1qCBFsZgqVa8_xlR04cSCpKmFZoV7P4_rhmikUewZ_w_imjWIABhpp3uKQ1Oq6BNhzNB0m_UaPBP7NrLJTdeen7rHSAkkKBnOTew8mXzrTSbNbSdWs3sOR45l77Bzp3RbfXca5cCeIxRwUkRZqQr3x4BtzB_dLU6L2s8s5SUEmcsmaCZPMWKN_tE/s640/IMG_4957.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaAab1qCBFsZgqVa8_xlR04cSCpKmFZoV7P4_rhmikUewZ_w_imjWIABhpp3uKQ1Oq6BNhzNB0m_UaPBP7NrLJTdeen7rHSAkkKBnOTew8mXzrTSbNbSdWs3sOR45l77Bzp3RbfXca5cCeIxRwUkRZqQr3x4BtzB_dLU6L2s8s5SUEmcsmaCZPMWKN_tE/s16000/IMG_4957.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">14 gauge wire<br /></td></tr></tbody></table><div>
<b>Tool List:</b></div>
<div>-chain breaker or a hammer, nail, and nut</div><div>-dish detergent</div><div>-(2) needle nose pliers <br /></div><div>-metal file (optional) <br /></div>
<div>
</div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I always think how cool a roller chain bracelet would look. Wanting a quick project, I finally made one. The biggest hurdle is the clasp.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Bracelet</b></span><br />I sized the chain to my wrist and use a chain breaker to shorten the chain. You don't want it too tight or too loose. I just wrapped the chain around my wrist and gave it some extra length. Make sure you break the chain so that an inside link and outsider plate meet. If you don't you'll need to add one length so the chain is continuous.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaDG4mXY7UOZRebpNYgMZT0kEYyGYU_ox_SmHWp210QDgJx6kU1onkagjhct1CzLM69t6CJ8nk56RpRFXJ5pEp2VrNPgeMnvDF1x7_XmdXbc9UdcctsRS6pl4AcdcJ8Y_KrGxeoEfEOS5OfWApgjYnJC6KO86582ePZJ6WUfRZlZOv18m0NfRajhC1Ucw/s640/IMG_4947.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaDG4mXY7UOZRebpNYgMZT0kEYyGYU_ox_SmHWp210QDgJx6kU1onkagjhct1CzLM69t6CJ8nk56RpRFXJ5pEp2VrNPgeMnvDF1x7_XmdXbc9UdcctsRS6pl4AcdcJ8Y_KrGxeoEfEOS5OfWApgjYnJC6KO86582ePZJ6WUfRZlZOv18m0NfRajhC1Ucw/s16000/IMG_4947.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Chain breaker setup<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIHy-DNHN3izuXB_HVg_B-UcEknq-hvqhPVDTF6tcstlDu0Ivijp3T0ynIACNCXRSRufZTlDX9IuPIc20Owp3ucbOmyZnqhpUohLQ-69gXyLSYBt1UAhMtEGQdP5qBBss-rPMi9s8HUYrkMwF4o0sdbka_u3OPkF_limM8Dns0UtUx4WhU7Dv-raEHvYg/s640/IMG_4948.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIHy-DNHN3izuXB_HVg_B-UcEknq-hvqhPVDTF6tcstlDu0Ivijp3T0ynIACNCXRSRufZTlDX9IuPIc20Owp3ucbOmyZnqhpUohLQ-69gXyLSYBt1UAhMtEGQdP5qBBss-rPMi9s8HUYrkMwF4o0sdbka_u3OPkF_limM8Dns0UtUx4WhU7Dv-raEHvYg/s16000/IMG_4948.jpg" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjLOsWutoI8tmaOZpByIM_R5AdEi-pCNW2aJezY1WE4bJ6TwmUZYQBN4HEpm06jp99UZr8c7AxEM4THYRLd0TfYd9MLnmyxZeWVyPleQfPK6xwE5UNO_Jg9a3vtVx0ia8KckabfbxJ1g9mam4k32Gw_i4WHUUxLuB7l_xGe1VAckQFPgQEPhnteQLB_Y8/s640/IMG_4949.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjLOsWutoI8tmaOZpByIM_R5AdEi-pCNW2aJezY1WE4bJ6TwmUZYQBN4HEpm06jp99UZr8c7AxEM4THYRLd0TfYd9MLnmyxZeWVyPleQfPK6xwE5UNO_Jg9a3vtVx0ia8KckabfbxJ1g9mam4k32Gw_i4WHUUxLuB7l_xGe1VAckQFPgQEPhnteQLB_Y8/s16000/IMG_4949.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Chain separated with pin<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEialELNEhJ4h2G1-BVGNr8WGVxOQh0J2DUOjkGjF2D3sgWghtYFdOq6Rv5-c3ow3gUb39lLc16rkvtqft9qrVo8PzynGjkcgGgaXM7ILYyTVEbllrrMvWHobQMT-lSzBJLSNMdBbG9bJvbKJrtf12YGcclKsKyxJmjXOg57DNmR2aL65S_umHKoaxgIz88/s640/IMG_4950.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEialELNEhJ4h2G1-BVGNr8WGVxOQh0J2DUOjkGjF2D3sgWghtYFdOq6Rv5-c3ow3gUb39lLc16rkvtqft9qrVo8PzynGjkcgGgaXM7ILYyTVEbllrrMvWHobQMT-lSzBJLSNMdBbG9bJvbKJrtf12YGcclKsKyxJmjXOg57DNmR2aL65S_umHKoaxgIz88/s16000/IMG_4950.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Budget chain breaker: nut, nail, and hammer<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQQCIpJU0Cw2oUW6tS5TN_tPfoVfdI3pFhleDS5KBTKpDmf9D0LSn-mEJwgE8BzZtBUxlhFM1sertdA_v63HmDMS_ZESLfZWMHab8DmlHZAvi3HMMatLuUW9qBaYP4GHRdepb-H-cB4nbekr5Qzp5g6yQ8EGRo3F1NJ-3xuuTHRSr_FhPVivkQLbo77Zg/s640/IMG_4964.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQQCIpJU0Cw2oUW6tS5TN_tPfoVfdI3pFhleDS5KBTKpDmf9D0LSn-mEJwgE8BzZtBUxlhFM1sertdA_v63HmDMS_ZESLfZWMHab8DmlHZAvi3HMMatLuUW9qBaYP4GHRdepb-H-cB4nbekr5Qzp5g6yQ8EGRo3F1NJ-3xuuTHRSr_FhPVivkQLbo77Zg/s16000/IMG_4964.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Straight the chain breaker post with a vice and hammer if needed<br /></td></tr></tbody></table><p>While a chain breaker is the easiest way, if you don't have one, you
can use a hammer, nail, and nut. It just takes longer. A chain breaker
has a clamp and rod to push the pin out of the chain. You twist the
threaded rod with a wrench to push the pin out. Without a breaker, I
place the nut below the pin, place the nail on the pin, and then hit it
as hard as I can with a hammer. It's not elegant, but it works.</p><p>Once
that was done I degreased the chain to remove any oil with dish soap.
Let it soak for a couple of minutes, then wipe it down with a shop towel.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Clasp</b></span><br />
I was thinking some kind of cotter pin and cotter pin and bolt setup. I
don't want this thing permanently on my wrist, but I also want it to
look professional. I also didn't want to buy anything. With those
parameters I searched through my parts bin and came up with some ideas.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1IWWir-ddo2xAbKb9LJuTQwGJkj_62MYoWuhFPQLTHhnPrq-8WfC150CkjwfM_keggihyLVKR-EO8L_6QSKV58DLwPLUept8TeitjbGJAKpMeDJIwP3ismciGQTVSQ8S41-Q6LRG5hB4YZfODFp2S8h_6Xl9YcvCTlioIKd9oCfPhzrNJsM9F429nVE0/s640/IMG_4952.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1IWWir-ddo2xAbKb9LJuTQwGJkj_62MYoWuhFPQLTHhnPrq-8WfC150CkjwfM_keggihyLVKR-EO8L_6QSKV58DLwPLUept8TeitjbGJAKpMeDJIwP3ismciGQTVSQ8S41-Q6LRG5hB4YZfODFp2S8h_6Xl9YcvCTlioIKd9oCfPhzrNJsM9F429nVE0/s16000/IMG_4952.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Potential pins from my hardware bins<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQPcscO8r-TYNtDxqglYRl8O1OpAnZ0fo_5VE0lLwHXqQfdzuE_Gbq_JF9m3JhghuDP-5cuHuA9P0SXsdUd5Y8897k8nF3d7aui91gPW2tUtFH-84yg-j5t9knoR_RK5rw0_BBd4laFlX2-LL2NPWmzjLYOFfutioLx-eUI5ajGEqbEPFfnrQBURm3sWs/s640/IMG_4956.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQPcscO8r-TYNtDxqglYRl8O1OpAnZ0fo_5VE0lLwHXqQfdzuE_Gbq_JF9m3JhghuDP-5cuHuA9P0SXsdUd5Y8897k8nF3d7aui91gPW2tUtFH-84yg-j5t9knoR_RK5rw0_BBd4laFlX2-LL2NPWmzjLYOFfutioLx-eUI5ajGEqbEPFfnrQBURm3sWs/s16000/IMG_4956.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Clasp 1 - a clip I had in my bins<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFwnZQ5KZyvn9-oJ355-hhphv5wh1jV5_J8AFx7Eqbd6SYJjXgR75iz-ZftgLL2QLVhKJiLEE3bxbjudRH3wAxvD79MoXQFGvVQbqVgJ2iexu6IsQFIcwzbY_kCDI0xAux0kN_ddi99Ah70HRfleZ5n2ZLitoydsU2qYz5MnE_iqJwYZzHWW_lTd6X9Jo/s640/IMG_4960.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFwnZQ5KZyvn9-oJ355-hhphv5wh1jV5_J8AFx7Eqbd6SYJjXgR75iz-ZftgLL2QLVhKJiLEE3bxbjudRH3wAxvD79MoXQFGvVQbqVgJ2iexu6IsQFIcwzbY_kCDI0xAux0kN_ddi99Ah70HRfleZ5n2ZLitoydsU2qYz5MnE_iqJwYZzHWW_lTd6X9Jo/s16000/IMG_4960.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Clip 2 - a 'C' clip<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmMd55jQXsEoEeE_VXxPovzBA2AabvGE0WekuGa-2IfhKQRRkyFwBpX5Yy-rWqho6J1bFgBIN7vm7O6B2H2stNj2KHzT6GAfUCVlAkqr62wKXH4s9GOi3_afegxpsj_YyoXtO0JoXTIXtv_R_vCtnOhRNUUWIjnwSCcsTqrOv3mQ0NTmWGPFyTRvH3RXo/s640/IMG_4959.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmMd55jQXsEoEeE_VXxPovzBA2AabvGE0WekuGa-2IfhKQRRkyFwBpX5Yy-rWqho6J1bFgBIN7vm7O6B2H2stNj2KHzT6GAfUCVlAkqr62wKXH4s9GOi3_afegxpsj_YyoXtO0JoXTIXtv_R_vCtnOhRNUUWIjnwSCcsTqrOv3mQ0NTmWGPFyTRvH3RXo/s16000/IMG_4959.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Final clip - a 'G' clip<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv80kh48hR3G2_oz3Khn9ZtM2cj_BYt7IJzFoQ2DKoOgGMtb6-jDzvAuaoCHmkSpX0leXzJWe3sJqWzhd86HsSeYukS3wfhKcza3ijR_MTJUH-H4gtjIfIyITw3GwqmYgmQfl3uJalwP5Lmf9Qp2bnhyialf-21yNE3rbpl4eHrOmf75UQf5osoF1Wquo/s640/IMG_4962.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv80kh48hR3G2_oz3Khn9ZtM2cj_BYt7IJzFoQ2DKoOgGMtb6-jDzvAuaoCHmkSpX0leXzJWe3sJqWzhd86HsSeYukS3wfhKcza3ijR_MTJUH-H4gtjIfIyITw3GwqmYgmQfl3uJalwP5Lmf9Qp2bnhyialf-21yNE3rbpl4eHrOmf75UQf5osoF1Wquo/s16000/IMG_4962.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Using (2) needle nose pliers to shape the wire<br /></td></tr></tbody></table><p> The alternative is to make the bracelet loose enough that it slides on and off, but that's too loose for my liking.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRVSeJw5pQGf7G3QWMonkk7Na-bHtfyXpHiYQ0GaNFhCvq7crDDCUd5ujECv6W_UIc-pjf0FGI58qBJu8cZlS5Yh7BVWk4aKmHIEDB22mEudGlafozwnnYm21CjmDsqGrtTdXoM-uASAfZKSAKZizXScMJWoWRMxBFt1fKVdRkM-lOPoSBEhtMcn5xIWU/s640/IMG_4961.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRVSeJw5pQGf7G3QWMonkk7Na-bHtfyXpHiYQ0GaNFhCvq7crDDCUd5ujECv6W_UIc-pjf0FGI58qBJu8cZlS5Yh7BVWk4aKmHIEDB22mEudGlafozwnnYm21CjmDsqGrtTdXoM-uASAfZKSAKZizXScMJWoWRMxBFt1fKVdRkM-lOPoSBEhtMcn5xIWU/s16000/IMG_4961.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Shape and overall size of the final 'G' clip<br /></td></tr></tbody></table><p>The 'C' clip worked best, but it was too long. I tried making my own 'C' clip but was concerned it would fall out. I
ended up using 14 gauge wire shaped in to an 'G' shape. I used needle
nose pliers to shape it, and the shape with the leg prevents the clasp from sliding
out. You could file the ends of the wire so they're less sharp. I
didn't, as they don't contact skin.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Finish</b></span><br />I
wish the clasp was the same color as the roller chain, but the bracelet
is secure and won't fall off. I made this with recycled parts, so I
didn't spend anything. That's always a plus.</p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-54534023436159900132023-11-03T02:00:00.520-04:002023-11-03T02:00:00.132-04:00Grim Reaper Costume Build<span face=""arial" , "helvetica" , sans-serif"><b>The World Weary Grim Reaper</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwKtF7FcOJMgyquqU2xv0LGN0_R5_vYWl7_VegYyvNL8DMYM8tJhQbRuaqD3jeFyniVfgtHNMed6I6g2sebIRcUKXi2ZkKylfsI6NW0icIJtbeAx15wCx3OoSjkvsY5I0EDHaY4ZO-pU05-R6FbqM9AHxXXr4XaUsEx7lPl_u2970iPYzwhmjp0NWcK48/s640/GRcover-res.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwKtF7FcOJMgyquqU2xv0LGN0_R5_vYWl7_VegYyvNL8DMYM8tJhQbRuaqD3jeFyniVfgtHNMed6I6g2sebIRcUKXi2ZkKylfsI6NW0icIJtbeAx15wCx3OoSjkvsY5I0EDHaY4ZO-pU05-R6FbqM9AHxXXr4XaUsEx7lPl_u2970iPYzwhmjp0NWcK48/s16000/GRcover-res.jpg" /></a><br />I wanted to design my own costume instead of basing a design on an <a href="https://withwardworks.blogspot.com/search/label/halloween" target="_blank">existing property</a>. The grim reaper is a classic Halloween character, and I wanted to put my own spin on it.<br />
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<b>Purchase List (paid links):</b><br />
<div></div><ul style="text-align: left;"><li><a href="https://amzn.to/37RUeep" target="_blank">EVA foam floor mats (4 pack)</a><br /></li><li><a href="https://amzn.to/37QKMb5" target="_blank">Craft foam</a></li><li><a href="https://amzn.to/37PSFxC" target="_blank">Grey wool blanket</a><br /></li><li>6 yards <a href="https://amzn.to/3e6lTJP">muslin perm press material</a><br /></li><li> .5 yards <a href="https://www.amazon.com/Barcelonetta-Craft-Supply-Costume-Decoration/dp/B07W8GT2G4/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=a921a518a96e2bc03f1f3fddae91cef7&camp=1789&creative=9325" target="_blank">fur material</a><br /></li><li><a href="https://amzn.to/385ThiX" target="_blank">Styrene plastic .04</a><br /></li><li><a href="https://www.lowes.com/pd/Silver-Line-Plastics-2-in-x-10-ft-280-PSI-Schedule-40-White-PVC-Pipe/5002105021" target="_blank">8'-0" 2" PVC pipe</a></li><li><a href="https://www.lowes.com/pd/Charlotte-Pipe-2-IN-SCH40-COUPLING/5012906607" target="_blank">(2) 2" PVC couplers</a><br /></li><li>5'-0" <a href="https://www.lowes.com/pd/Charlotte-Pipe-3-4-in-dia-x-5-ft-L-480-PSI-PVC-Pipe/3133087" target="_blank">3/4" PVC pipe</a><br /></li><li>Plastic skull mask</li><li>Skeleton gloves</li><li><a href="https://www.amazon.com/Wirrabilla-Cockroaches-Realistic-Lifelike-Halloween/dp/B0B5XSJX92/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=14783aaf49e73bd90d594e6651cdd4ef&camp=1789&creative=9325" target="_blank">Fake cockroaches </a><br /></li><li><a href="https://amzn.to/3GDTAQQ" target="_blank">Black plastic chain</a><br /></li><li>(1) <a href="https://amzn.to/3myH6la" target="_blank">black dye</a></li><li>(1) brown dye<br /></li><li>(1) <a href="https://amzn.to/3pPgjmW" target="_blank">scarlet dye</a></li><li>Play sand <br /></li><li><a href="<a target="_blank" href="https://www.amazon.com/Diffused-Lighting-Electronics-Components-Emitting/dp/B01C3W6NSK/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=d999306c8be28bc7476b07f03735f895&camp=1789&creative=9325">a</a>" target="_blank">1/8" red and yellow LED lights</a></li><li><a href="https://www.amazon.com/JWISLAND-Battery-Holder-Leads-Mount/dp/B0BZMLJZY3/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=b2bd1efa7d1d7e38d2820f9d094d38fd&camp=1789&creative=9325" target="_blank">(4) Battery holder with leads</a><br /></li><li><a href="https://www.amazon.com/AmazonBasics-16-Gauge-Speaker-Wire-Feet/dp/B006LW0W5Y/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=2a6c95b524ac2d0ee696f9dc0f70f2e2&camp=1789&creative=9325" target="_blank">16 gauge wiring</a><br /></li><li>(2) 2 liter soft drink bottles</li><li><a href="<a target="_blank" href="https://www.amazon.com/Twisted-Natural-Decoration-Hammock-Hanging/dp/B09TN9HXWJ/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=712528c5a42084cf3ecb1547846948f9&camp=1789&creative=9325">a</a>" target="_blank">1/2" cotton black braided rope</a><br /></li><li>(7) Buttons, I salvaged these </li><li><a href="<a target="_blank" href="https://www.amazon.com/Sunglasses-Classic-Vintage-Style-Design/dp/B078PQTML8/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=d1d9b80717268bccff1d58ebcfdf795f&camp=1789&creative=9325">a</a>" target="_blank">Cheap black sunglasses</a><br /></li><li><a href="https://amzn.to/34PVUmP" target="_blank">1" hook & loop non-adhesive velcro</a><br /></li><li><a href="https://amzn.to/3oRB2Ub" target="_blank">Acrylic caulk</a><br /></li><li>(4) 14" - <a href="https://www.lowes.com/pd/Hillman-5-16-in-dia-x-3-ft-L-Coarse-Steel-Threaded-Rod/3129281" target="_blank">5/16"-18 threaded rod</a><br /></li><li>(16) <a href="https://www.lowes.com/pd/Hillman-5-16-in-x-18-Zinc-Plated-Steel-Hex-Nut/3058549" target="_blank">5/16"-18 nuts </a><br /></li><li><a href="https://amzn.to/2JxrugZ" target="_blank">Plasti-dip spray paint (2) cans</a><br /></li><li><a href="https://amzn.to/3mLPZFs" target="_blank">Rustoleum spray paint</a>
(1) can each (6 total): satin Chestnut Brown, Flat Burgundy, Metallic Silver, Metallic Gunmetal, satin Beige, flat Black<br /></li><li><a href="https://amzn.to/386lh5P" target="_blank">Acrylic paints</a>: black, white, brown, red</li><li><a href="https://www.amazon.com/Kangaroo-Jumping-Fitness-Exercise-Bouncing/dp/B00M3Y8ZFS/?&_encoding=UTF8&tag=ward05-20&linkCode=ur2&linkId=06ba52f8b51ed005d3433edf82801721&camp=1789&creative=9325" target="_blank">Jumping stilts</a> (these are normally $300. I got lucky and found them years ago for $40 on Craigslist) <br /></li></ul>
<b>Total: $340 starting with nothing/ I spent $80 as I already had a most of this stuff, and it's likely you do too. I bought the mask, gloves, the blanket, and the perm press material<br /></b><div>
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<b>Tool List (paid links):</b></div><div><ul><li>band saw</li><li>sewing machine, black thread<br /></li><li>dremel with sanding drum</li><li>drill with 1/8" bit, 5/32" bit<br /></li><li>hot glue gun</li><li>heat gun to seal the foam</li><li>belt sander <br /></li><li><a href="https://amzn.to/3kSs8DC" target="_blank">seam ripper</a></li><li><a href="https://amzn.to/3eq3GXQ" target="_blank">rotary cutter</a></li><li>scrap paper for sketching and for protecting work surfaces</li><li>pencil (I prefer a <a href="https://amzn.to/3jXMA4p" target="_blank">lead holder</a>)</li><li>pens</li><li>markers</li><li>tape measure <br /></li><li>painters tape</li><li>duct tape </li><li>hobby knife with replacement blades</li><li>metal straight edge <br /></li><li>cutting mat</li><li>contact cement</li><li>shop towels</li><li>respirator with organic vapor cartridges - contact cement is toxic, so is spray paint <br /></li></ul></div>
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</div><p><span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />
While I typically start my projects in Sketchup, most of this project was sketched by hand as the robe doesn't lend itself to digital drafting. I did design the scythe and hour glass in Sketchup to figure out the scale. This lets me figure it out before I start cutting. I always try to maximize quality and cost.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Robe & Tabard</b></span><br />I wanted a tattered and old look to the robe. I want this grim reaper to look like he's been around hundreds of years. I started with a paper pattern, sketching, adding, and cutting until it looked right. I had to pattern in conjunction with the stilts so that the robe would be long enough to cover my feet when wearing the stilts. The robe needed to hang about 8" longer to cover my feet. I wanted it baggy, and I wanted the sleeves to be large. The sleeves also taper wider towards the end.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixhuOtadyBCW86m2fd6JzvE2ylU97ogRj-GjZAMfpB28N9aCnR1zrYzkhHRbT44aDmwxRT0AAKGmte1puilK7I5Sh6KeOdhwuvJx9QRvQRR_lIbXEzYocTW70FuoFz0BIlFKUU-zW7KOsjbxt561ha9mKcuN4cgAtMrkRDN1HJNRTPoYl7kzN5vSWnL1o/s640/IMG_4617.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixhuOtadyBCW86m2fd6JzvE2ylU97ogRj-GjZAMfpB28N9aCnR1zrYzkhHRbT44aDmwxRT0AAKGmte1puilK7I5Sh6KeOdhwuvJx9QRvQRR_lIbXEzYocTW70FuoFz0BIlFKUU-zW7KOsjbxt561ha9mKcuN4cgAtMrkRDN1HJNRTPoYl7kzN5vSWnL1o/s16000/IMG_4617.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Robe paper pattern in progress<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhggSvHhJWycXy9RyS_cfyfr6ELTjMDV0lTdMMwGUI7BIdLBvANuETLdapXQBryuxHamSXhG8RhwtOnPGGuVMHuTnTVkDNlG_iGU5-KxDbXi2cvgTxyQOvCU5QqtheXO9hy8z0a1etYYkrHO44RhFAvZSIY7tqQXslAifxQuHBYH4O8HBNAMQO1aSxmjTE/s640/IMG_4620.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhggSvHhJWycXy9RyS_cfyfr6ELTjMDV0lTdMMwGUI7BIdLBvANuETLdapXQBryuxHamSXhG8RhwtOnPGGuVMHuTnTVkDNlG_iGU5-KxDbXi2cvgTxyQOvCU5QqtheXO9hy8z0a1etYYkrHO44RhFAvZSIY7tqQXslAifxQuHBYH4O8HBNAMQO1aSxmjTE/s16000/IMG_4620.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hood and robe paper pattern test fit<br /></td></tr></tbody></table><p> </p><p>I added a red lining half way up the sleeves as I wanted red accents throughout the costume. I didn't fold the edge and sew the liner because I wanted a ragged look to the sleeves. I did tack the liners in four spots around the sleeves just so it would stay in place. Otherwise the liner will 'fall out.' The robe is a perm press material. I really like the weave of the material. I didn't mark patterns and opted to do it by eye as I wanted this to look like the grim reaper has maintained this for centuries. It came out better than expected and was much quicker.<br /></p><p>I opted for buttons to fasten the robe as I knew the tabard would cover them. I also didn't want the stilts to pull against the fabric and cause the velcro to be noisy. I used 6 buttons, roughly 11" on center. My sewing machine didn't have the right end to sew buttons, so I stitched a line on all four sides and cut the opening for the button.<br /></p><p>The best way to do the neck opening is a separate piece so you can sew the curve and not bunch the material. I did manage to make the neck opening a bit too large. Since I used the robe pattern as a starting point for the tabard, that neck opening is too large too. The only other issue with the robe is it would have been nice to slit the side seam so I had easier access to my pockets. It would just be a pass through opening.<br /></p><p>To give the costume an imposing look, I added EVA foam shoulder pads to the robe. I hand stitched them to the top seam to keep them in place. They are right at the end of the sleeve stitching, making my shoulders broader and taller. I used a heat gun to shape the shoulder pads. <br /></p><p>I dyed the robe with black dye. I mixed a little bit of brown for flavor and to stretch my black. I knew the pot I was using wasn't large enough. The dye instructions state half a bottle per pound of fabric with dish detergent and salt. I had quite a few pounds of fabric and only used half a bottle of black and a quarter of brown. I knew my pot was too small, and hoped that would create a faded pattern. It did. I like there are areas where the robe is a bit light.<br /></p><p>I used the robe pattern as a starting point for the tabard. I wanted a tabard to make the costume look more like a warrior and create layers. I made it shorter than the robe because I wanted the robe below visible. The tabard has four splits - front, back, and both sides. They slit up to mid thigh and reveals the robe underneath. I did stitch a line at the top of each slit to prevent tearing. I couldn't find a black wool blanket, and I had trouble dying wool a couple years ago, so I sprayed it with black spray paint. I used velcro along the front to close the tabard. The wool just seems like the right material, I like it.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidDBQdAPbvivKWIQRuWvd3ic8Bf3nSeilE0u4I91u8-IFmcxN0u-AAGlBfdCynWgI4ercJJdKmGgtWKMqJGyBOTWkph8oq-dJnxaJox_dkP9q2NJbrImEIDi4VMcyf8ijw1Ud1TXHERwt4ddgI3lLMpr7q4XtyaNnjqXZTFjNZXderdHEX9YoCPiS_6LY/s640/IMG_4885.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidDBQdAPbvivKWIQRuWvd3ic8Bf3nSeilE0u4I91u8-IFmcxN0u-AAGlBfdCynWgI4ercJJdKmGgtWKMqJGyBOTWkph8oq-dJnxaJox_dkP9q2NJbrImEIDi4VMcyf8ijw1Ud1TXHERwt4ddgI3lLMpr7q4XtyaNnjqXZTFjNZXderdHEX9YoCPiS_6LY/s16000/IMG_4885.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Robe fake bugs<br /></td></tr></tbody></table><p>I initially planned to do a ragged skirt between the robe and tabard. I wanted to split it into 3" strips, but the tabard would cover too much of it and make it pointless.</p><p>I added fake cockroaches to the robe at the bottom of the robe and on the sleeves. I did this by hand, looping the thread around the bug's head and then creating a few loops through the robe. I also weathered the bottom edge of the robe and tabard on a belt sander. The goal was an irregular pattern to make both look old and worn, like they've been dragging the ground forever. I used the belt sander to create holes, thin spots, tears, and a ragged edge. I did two passes, as after the first pass the robe and tabard didn't look worn enough.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Hood</b></span><br />The hood is one of the most important parts. I knew I wanted a red lining just to highlight the skull mask. I used my <a href="https://withwardworks.blogspot.com/2021/11/scorpion-mortal-kombat-11-costume-build.html" target="_blank">Scorpion</a> costume as a basis to sketch out a paper pattern as I really like that hood. I wanted the hood to peak farther than possible. I used .04 plastic between the red liner and black hood. I sewed it in a few places to keep it in place. The sewing machine sews right through this thin plastic. I extended the hook about 8" past my head. That was the look I wanted. I also didn't fold the edge when I sewed it for a ragged look.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbANPKODyQhUvpZ3448KHWbGCLM9bv6-TZ1dH4UUqTOTWaMgD7sfFPT2o6C2QNo7nrw_D4UeujAqcErcTuXtVFwXGTLyR5iTnBGLMwnpgyyswgar24ParefZH0XqrQl2cygkL5294VMj2Dv9VnQUKWmxNhQbVsbCg26Dl9vyEJGhyphenhyphenPUWodKzIP6ACcIrU/s640/IMG_4607.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbANPKODyQhUvpZ3448KHWbGCLM9bv6-TZ1dH4UUqTOTWaMgD7sfFPT2o6C2QNo7nrw_D4UeujAqcErcTuXtVFwXGTLyR5iTnBGLMwnpgyyswgar24ParefZH0XqrQl2cygkL5294VMj2Dv9VnQUKWmxNhQbVsbCg26Dl9vyEJGhyphenhyphenPUWodKzIP6ACcIrU/s16000/IMG_4607.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hood pattern<br /></td></tr></tbody></table><p> </p><p>I added a bottom piece of trim to cover the neck opening. I sewed it to the hood and added a button on the inside to fasten it. <br /></p><p>My only issue with the hood is that the back of the hood curves a bit too late, it needs to be shorter to better fit my head.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Mask and Gloves</b></span><br />I bought the mask, knowing I would paint it. I cleaned it first and then sprayed it in a light beige/tan. Bone has more of a beige color instead of white or gray. I used black oil paint to give it a messy look and around to blend the eyes. Oil paint won't wipe off as easy, but I wanted this messy looking. I especially wanted black around the eyes to blend in the lenses. I used cheap sunglasses lenses hot glued to the inside of the mask. With the paint it's nearly seamless. I also added extra padding to the forehead and cheeks so it fit better.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVQH2YGwLjDffvVHItGiNfRRniE6DxJetqDSkb2vYlCvw-fy0ZQFCh2oTvFhodm1XwgcDbDSGyVpHUaaaOi3bvrkGvmFFamEPQ07SjMw-CF5C_9XrVj8Ztw-auYJF6Oi8Gg8T_vFK5AQpqZogbrwPxa0Kh4bKm3et6KdEsNDqIJYoHOEEwZbKMzhBkIBM/s640/IMG_4658.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVQH2YGwLjDffvVHItGiNfRRniE6DxJetqDSkb2vYlCvw-fy0ZQFCh2oTvFhodm1XwgcDbDSGyVpHUaaaOi3bvrkGvmFFamEPQ07SjMw-CF5C_9XrVj8Ztw-auYJF6Oi8Gg8T_vFK5AQpqZogbrwPxa0Kh4bKm3et6KdEsNDqIJYoHOEEwZbKMzhBkIBM/s16000/IMG_4658.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Mask first paint pass</td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8SfM7LNNkM-2McsTWctQBFHrpUpChd3fRb4rriaUjbLPLtBczz_K933NIr2BL3h-ZbJg4AlYINr4q7Dc8Bv6kQvc_i7snDhsKFZE4n8s65MjqsXLke2E43t9A1rQMlIVns0suzDO8a_Lw_k3ZWgunj3g9zXEe-9A5QEFY_KcBiipaKxU1M1xKtw2xR_w/s640/IMG_4662.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8SfM7LNNkM-2McsTWctQBFHrpUpChd3fRb4rriaUjbLPLtBczz_K933NIr2BL3h-ZbJg4AlYINr4q7Dc8Bv6kQvc_i7snDhsKFZE4n8s65MjqsXLke2E43t9A1rQMlIVns0suzDO8a_Lw_k3ZWgunj3g9zXEe-9A5QEFY_KcBiipaKxU1M1xKtw2xR_w/s16000/IMG_4662.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Mask paint complete</td></tr></tbody></table><p> I added yellow, brown, and red acrylic paint to dirty up the mask and give it a bit of a story. The mask came out really well. It's one of my favorite pieces. I also added (4) red LEDs to the back of the mask, so the hood glows a bit. I had a AA battery pack that I quickly wired in placed with 16 ga wire. I just twisted the wire tight to the LED leads. It's not a great job, but it got the job done. I pull the batteries to cut the lights on/off. I did hot glue a piece of black material to the inside bottom edge of the mask just to cover my neck. It makes the head look like it's floating, which I really like.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg83e0p78yPFtwX0VO7hnk2-jS-ZHsytKYOG8LmZjycM8MyvcTFcm3gqZ_DpSO_xJ21FpafCluDMzMbdzZwSSy_5cqBDR9MqPwZpVJchfb86kRoy_Lhfsd3E-TuI4WkGzrcfkmQriuYj2ivlkgpZg-mnQgMt9DVIrtYx3wnCcCHVfQZpjVNq9mWRtly_j0/s640/IMG_4869.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg83e0p78yPFtwX0VO7hnk2-jS-ZHsytKYOG8LmZjycM8MyvcTFcm3gqZ_DpSO_xJ21FpafCluDMzMbdzZwSSy_5cqBDR9MqPwZpVJchfb86kRoy_Lhfsd3E-TuI4WkGzrcfkmQriuYj2ivlkgpZg-mnQgMt9DVIrtYx3wnCcCHVfQZpjVNq9mWRtly_j0/s16000/IMG_4869.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Mask complete<br /></td></tr></tbody></table><p></p><p>I purchased the gloves but painted them to dress them up. Black paint in the joints and smears of black to dull the bright white makes them look used and worn.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia49Ik4KyZZGHunOCiBRMcbHRxaw2VQAGxSDx-xTaGUCGW4oUyF4Hehq4G4eivixEqXnPG64JrqKcRemcLJotg2Auu4nCrOHzqL6wfppMlHdOFcBK_dSManDLRKBh2MqKNyTFkD2qUP0USTry6KNHqZn8gY4AHSPM1216y-CFTptN77BluAGraHl4niEw/s640/IMG_4675.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia49Ik4KyZZGHunOCiBRMcbHRxaw2VQAGxSDx-xTaGUCGW4oUyF4Hehq4G4eivixEqXnPG64JrqKcRemcLJotg2Auu4nCrOHzqL6wfppMlHdOFcBK_dSManDLRKBh2MqKNyTFkD2qUP0USTry6KNHqZn8gY4AHSPM1216y-CFTptN77BluAGraHl4niEw/s16000/IMG_4675.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Gloves after and before paint<br /></td></tr></tbody></table><p>
</p><p><span face=""arial" , "helvetica" , sans-serif"><b>Scythe</b></span><br />You can't be the grim reaper without a scythe. From the start I was thinking eight feet tall with a four foot long blade. I wanted this to be huge. With the additions of the stilts, the blade would still be taller than I was, which worked. I originally was thinking the handle would be 3/4" PVC, but with the addition of stilts, the 3/4" PVC isn't large enough to help me balance. It bends and flexes under my weight. I had 2" PVC on hand and drawing it in Sketchup, the 2" handle scales better.</p><p>The cross handle and blade is 3/4" PVC. I did heat up the end of the PVC for the blade to flatten it. I used a coupler and drilled out for the cross handle. Another coupler was used at the top. I drilled a hole at an angle to catch the blade. I wanted the PVC to go completely through the coupler for stability.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI29QeFBhACvSsTQSbWTTPtuKs2hPViUTmnQtE6-FPbWCgBIFdXtPm6vExaNJE5Yj1sMbYq3Fd6Rn-DddTjq3vmj0fVp_eG6DUw6Zb9FLVUqJnOeVMw6VV8-eOFoK8O9QEYDgHQ1Kbw4vbleaI-wNpMg7ZZbHViLYLN-_FuIJm5d3DVZRqtadbjExF_4E/s640/IMG_4639.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiI29QeFBhACvSsTQSbWTTPtuKs2hPViUTmnQtE6-FPbWCgBIFdXtPm6vExaNJE5Yj1sMbYq3Fd6Rn-DddTjq3vmj0fVp_eG6DUw6Zb9FLVUqJnOeVMw6VV8-eOFoK8O9QEYDgHQ1Kbw4vbleaI-wNpMg7ZZbHViLYLN-_FuIJm5d3DVZRqtadbjExF_4E/s16000/IMG_4639.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Scythe PVC skeleton<br /></td></tr></tbody></table><p>The main blade is EVA foam. I cut a 45* angle on the inside of the foam 3" up the length of the blade so the bottom angles in to a point. I used contact cement to attach the foam to itself and to the PVC skeleton with a 1" foam spacer at the top to account for the 3/4" PVC. Wear a respirator when working with contact cement.<br /></p><p>I was going to cover the entire post in foam, but that requires a lot of foam. I ended up using craft foam for the top half, and painting the PVC for the bottom half. I layered the craft foam at the couplers for a smoother transition. Heat treat the foam before paint. This seals it so it absorbs less paint. You'll know it's sealed when the foam changes color.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGRzC0wp8uA8hfZHQtO6ZSeqvJyGMltbotAP5s3ra-xQ_LWpX8e7bxgmYXQkKCyE_Mwr5b9qLHybZhyphenhyphenw21krnc1IGDrDu7WfFrNvNXi1h6Pn-GVkTrlkzZEWiNZ5c4gqc-w6HtQwDoNEbez-gToEQgfjqjezfadiB35xvgQQDq-1e52XbpMaC6t-2JZSo/s640/IMG_4649.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGRzC0wp8uA8hfZHQtO6ZSeqvJyGMltbotAP5s3ra-xQ_LWpX8e7bxgmYXQkKCyE_Mwr5b9qLHybZhyphenhyphenw21krnc1IGDrDu7WfFrNvNXi1h6Pn-GVkTrlkzZEWiNZ5c4gqc-w6HtQwDoNEbez-gToEQgfjqjezfadiB35xvgQQDq-1e52XbpMaC6t-2JZSo/s16000/IMG_4649.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Scythe blade in foam<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyQtDAJ99etptr1LwnXH2K7dvRgoEpsY54i7QAB68uZs7LfYOOKvptGhl5EZZyGXsqWkORr1EAj-_Vb2gpHzs4FYB3qHXiEUsNs04azCzUSltcUTW8VfbOCpG2Ne_aWZhXBulztb988O2m7BdOw2i7pzIfpI1vVdYm94OzTET8BVuUZGSSzGDsB4XaYog/s640/IMG_4672.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyQtDAJ99etptr1LwnXH2K7dvRgoEpsY54i7QAB68uZs7LfYOOKvptGhl5EZZyGXsqWkORr1EAj-_Vb2gpHzs4FYB3qHXiEUsNs04azCzUSltcUTW8VfbOCpG2Ne_aWZhXBulztb988O2m7BdOw2i7pzIfpI1vVdYm94OzTET8BVuUZGSSzGDsB4XaYog/s16000/IMG_4672.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Scythe blade attached to pole<br /></td></tr></tbody></table><p> </p><p>I painted the whole thing with black plasti dip. The blade I painted a gunmetal silver, and then on the blade edge sprayed bright silver. I misted a bit of brown and burgundy on the blade to give it a dirty look. For a bit of dirt I hold the paint can farther away and only do a few quick squeezes of the trigger. Go slow with weathering. It's easy to go too fast and too much. The good thing is with weather is that you can wipe if off and the smears can add to the look.<br /></p><p>The handle is black plastic dip with a misting of brown, beige, and burgundy. I like all of the props to look a bit dirty and used. Misting paint achieves that. When props look to clean and new they look fake.<br /></p><p>I added the piece of red cloth to give the scythe character. Is it some kind of flag? A piece of material from a victory or enemy? Whatever it is, it looks cool.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWkHRSQ5Vmz7BZoDupXm3F3kGYGGsEtHs1V1il3H6PppEPy7sLTQ15q_CrQ55oeZvNMsYJ0beXFZCSbdnCOHLTsQzivtaKCv93ueDQNj2pD9kaIFEoF7WPnOW2sHx3JOOLV9Kg4Z5W8mMLfm1UWFTQHzEpN48DhzuAkzKNJAytlRzsNMxzhDnMClG1w1s/s640/IMG_4852.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWkHRSQ5Vmz7BZoDupXm3F3kGYGGsEtHs1V1il3H6PppEPy7sLTQ15q_CrQ55oeZvNMsYJ0beXFZCSbdnCOHLTsQzivtaKCv93ueDQNj2pD9kaIFEoF7WPnOW2sHx3JOOLV9Kg4Z5W8mMLfm1UWFTQHzEpN48DhzuAkzKNJAytlRzsNMxzhDnMClG1w1s/s16000/IMG_4852.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Scythe complete<br /></td></tr></tbody></table><p><span face=""arial" , "helvetica" , sans-serif"><b>Hour Glass</b></span><br />An hour glass represents times up, and I also wanted it to act as a lantern with the grim reaper leading you to the under world.</p><p>The hour glass has a 1/8" wood top and bottom plate with (4) threaded rods and nuts to hold the shape. I applied foam with a chamfer to get the top and bottom shape. Adding more foam to build up the base. For the pedestals, I cut foam triangular and at an angle to achieve a curve. I needed 8 tapered columns for the top and bottom. I then cut the top and bottom on a band saw to flatten it out. You need to cut the taper tangent to the curve of the taper. I just eyeballed it, but you can't cut it with the taper flat on the table. I kept adding bits until it looked decorative enough, like the trim at all the corners. I used contact cement to attach all the pieces. Wear a respirator when working with contact cement.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnL6CtVKYZPUuMM8fjhZxf1OiFl6nWSFyNl-7CkUVTk-p701MaGkvme0Z-pxF7p3jkps0jLX9KegeaMve9V8rIPYPZh70Yiznqyr_0txdOVOAbb35cf1nzOS0bjSpV6Nncj02zx04UmJvB4iBaexmt2YiDc0D4OrIkfJ1GTVZu0KTaYGvjMj6Ha5Qo_Zs/s640/IMG_4685.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnL6CtVKYZPUuMM8fjhZxf1OiFl6nWSFyNl-7CkUVTk-p701MaGkvme0Z-pxF7p3jkps0jLX9KegeaMve9V8rIPYPZh70Yiznqyr_0txdOVOAbb35cf1nzOS0bjSpV6Nncj02zx04UmJvB4iBaexmt2YiDc0D4OrIkfJ1GTVZu0KTaYGvjMj6Ha5Qo_Zs/s16000/IMG_4685.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hour glass frame<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhf19ecOngBEA9McOQ3BGz0waOWXQZIx7h5AILTio66m19RXkJkw_j-1J7BZUyssZcS7i0M0F2hd-Zrwku0kyqr_5tGixs7e-evnLOGb-szK9FW5bsAJBOPg6Mc14vLzsneCUeBoAkGEGkvGDNP5XsKvkquq2NP0wpiMZWOJyt6vucUqUhg1IptW3KAfwU/s640/IMG_4708.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhf19ecOngBEA9McOQ3BGz0waOWXQZIx7h5AILTio66m19RXkJkw_j-1J7BZUyssZcS7i0M0F2hd-Zrwku0kyqr_5tGixs7e-evnLOGb-szK9FW5bsAJBOPg6Mc14vLzsneCUeBoAkGEGkvGDNP5XsKvkquq2NP0wpiMZWOJyt6vucUqUhg1IptW3KAfwU/s16000/IMG_4708.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hour glass foam base and pedestals<br /></td></tr></tbody></table><p></p><p>The hour glass portion is (2) clear plastic two liter drink bottles cut to fit. I cut a notch in the foam top and bottom plate, applied hot glue and then set the bottles in place to prevent leaks of the sand.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZz9a8I9tIrRQrfJvtCkU1Btb7a_c88fzdnkWDtPDoMW98_0A4PXpUjIc1nxolsIyEaZe62YorRINgexL-q_9MKLsjEln62OOx-F-Za10dwpFK85rnIA25QTrhGfot793X2rIYWGGhOROSlZaTztI4n1M2QGm4kcezOI6Zz66ri_E1buVORPud9bEA22U/s640/IMG_4712.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZz9a8I9tIrRQrfJvtCkU1Btb7a_c88fzdnkWDtPDoMW98_0A4PXpUjIc1nxolsIyEaZe62YorRINgexL-q_9MKLsjEln62OOx-F-Za10dwpFK85rnIA25QTrhGfot793X2rIYWGGhOROSlZaTztI4n1M2QGm4kcezOI6Zz66ri_E1buVORPud9bEA22U/s16000/IMG_4712.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hour glass in foam<br /></td></tr></tbody></table><p> </p><p>I took regular play sand and put it in a red dye bath. It did take a few days for it to dry. I'm glad I didn't wait until the last minute for that! I couldn't finish the hour glass until the sand was added. Once the sand was added, I glued the bottles together. I initially planned to cut the thread tops so the larger flange would meet and I forgot. I contact cemented them and then used hot glue and foam around the threads. The only change I would make is I wish I had added a piece of plastic where the bottles meet with a smaller hole so the sand didn't drain so quickly. It drains in seven seconds. I used acrylic caulk where the bottles meet the foam to ensure no sand escaped.<br /></p><p>For the handles, I used 1/2" braided rope. I cut a small hole in the foam and it tension fits.</p><p>To fufill the lantern portion of this, I drilled (8) holes around the bottle on both ends. I drilled the wood plate and foam for 1/8" yellow LEDs, then drilling the wood plate with a 5/32" bit. I wanted the LEDs flush with the plate. They look good at night reflecting off the bottle, but don't show up during the day. To wire them, I looped and pulled the wire tight around the LED leads, adding hot glue to keep the wire in place. I thought about adding a switch, but didn't want to detract from the design of the hour glass. To cut it off and on I remove the battery.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxd7jYW1EhdH7vd9m5-2oC-nQsOobmO-gmVtNb54GH7BQVUsCH6JaUmXh5LoVC40hdaXbhtp4ohjqcHSny3-QI_IMaJ_ayM9PBgj88bO-nNUAKUuzlTplIhG0C9IIsFiMZerRdzw_lf9ExPaTVpL8fyO39C58SdXtIozDC4VjaTcbyF-YFXQyilFTvCLU/s640/IMG_4884.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxd7jYW1EhdH7vd9m5-2oC-nQsOobmO-gmVtNb54GH7BQVUsCH6JaUmXh5LoVC40hdaXbhtp4ohjqcHSny3-QI_IMaJ_ayM9PBgj88bO-nNUAKUuzlTplIhG0C9IIsFiMZerRdzw_lf9ExPaTVpL8fyO39C58SdXtIozDC4VjaTcbyF-YFXQyilFTvCLU/s16000/IMG_4884.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hour glass lights<br /></td></tr></tbody></table><p></p><p>I glued small triangles in the corners of the top and bottom so that the top and bottom plate snap into place so I can still access batteries.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKLkybXzt71FFE6s9pcKjGg2il3P4JBRnZBjihot3kycawtWWIawcyu8ntw-D-7d224er0hMUfFAPkV1BhZPRtDC1nTKhze1A52goi5Oy_-_7sWr1ymjvubg9rLbAzgaB8U9FbJGrWQlM2pjIBsQFHEMHIFUcbCLsSjIH7zqoMMFS-nhIME8NzgpoVKLw/s640/IMG_4883.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKLkybXzt71FFE6s9pcKjGg2il3P4JBRnZBjihot3kycawtWWIawcyu8ntw-D-7d224er0hMUfFAPkV1BhZPRtDC1nTKhze1A52goi5Oy_-_7sWr1ymjvubg9rLbAzgaB8U9FbJGrWQlM2pjIBsQFHEMHIFUcbCLsSjIH7zqoMMFS-nhIME8NzgpoVKLw/s16000/IMG_4883.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hour glass- triangles in each corner hold the plate in place<br /></td></tr></tbody></table><p>Heat treat the foam before paint. This seals it so it absorbs less paint. You'll know it's sealed when the foam changes color. I painted it with black plasti dip, then misted it with burgundy, brown, and beige. The burgundy continues the red accent, it's subtle but noticeable.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9pzFqV1nrgx9UlMsQDdPrCLW0ghe9zGc6j5wNxCS_NhOiD2319HV3k4hhtr57xhvZsP6kKLVhiDLKJhTC9cUtuR5myLZImC4h0w_MGu6tY0s6TKqA-LZR5Be_kZbqFmIOkNM0RL3ceL3aWugn5MbU6Tepp7oPwXWOJSN4rzuPeN_kRd8uw2hMkPZIb6c/s640/IMG_4868.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9pzFqV1nrgx9UlMsQDdPrCLW0ghe9zGc6j5wNxCS_NhOiD2319HV3k4hhtr57xhvZsP6kKLVhiDLKJhTC9cUtuR5myLZImC4h0w_MGu6tY0s6TKqA-LZR5Be_kZbqFmIOkNM0RL3ceL3aWugn5MbU6Tepp7oPwXWOJSN4rzuPeN_kRd8uw2hMkPZIb6c/s16000/IMG_4868.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hour glass - finish and LEDs<br /></td></tr></tbody></table><p><span face=""arial" , "helvetica" , sans-serif"><b>Chain & Padlock</b></span><br />I liked the metaphor of a padlock. The grim reaper is trapped in this job. The padlock is EVA foam. It kept getting thicker to account for lights, batteries and wiring. Initially I planned for it to be (2) mats thick but it ended up being (4) thick. I have (3) red LEDs in the lock opening with piece of black paper to diffuse the light.</p><p>A belt sander flattened all the edges as my patterns were off. <br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDLuKH7dSCJflzKMpl1Ed3MQyCiJf7mWrs0pSBeptP8BPWzF6USNIxkPyk4dr_SBFvtsBvQEbb-ACa-rakRd_lugJwIfqY9Wx8Cz92NxUNALMKdIF61ZHJ9x2GcALGeLsPM_w7iOKHEY2fcPjQVjQGsxC0jYXsAglREIHP4o6pemiK-XPI59m0VXGXjgI/s640/IMG_4595.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDLuKH7dSCJflzKMpl1Ed3MQyCiJf7mWrs0pSBeptP8BPWzF6USNIxkPyk4dr_SBFvtsBvQEbb-ACa-rakRd_lugJwIfqY9Wx8Cz92NxUNALMKdIF61ZHJ9x2GcALGeLsPM_w7iOKHEY2fcPjQVjQGsxC0jYXsAglREIHP4o6pemiK-XPI59m0VXGXjgI/s16000/IMG_4595.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Padlock<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbANPKODyQhUvpZ3448KHWbGCLM9bv6-TZ1dH4UUqTOTWaMgD7sfFPT2o6C2QNo7nrw_D4UeujAqcErcTuXtVFwXGTLyR5iTnBGLMwnpgyyswgar24ParefZH0XqrQl2cygkL5294VMj2Dv9VnQUKWmxNhQbVsbCg26Dl9vyEJGhyphenhyphenPUWodKzIP6ACcIrU/s640/IMG_4607.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbANPKODyQhUvpZ3448KHWbGCLM9bv6-TZ1dH4UUqTOTWaMgD7sfFPT2o6C2QNo7nrw_D4UeujAqcErcTuXtVFwXGTLyR5iTnBGLMwnpgyyswgar24ParefZH0XqrQl2cygkL5294VMj2Dv9VnQUKWmxNhQbVsbCg26Dl9vyEJGhyphenhyphenPUWodKzIP6ACcIrU/s16000/IMG_4607.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Padlock wiring in progress<br /></td></tr></tbody></table><p> </p><p>The wiring loops around the LED leads with a switch on the back to switch it off and on.</p><p>The padlock was heated treated and painted with black plasti dip. I dry brushed silver around the edges and on the craft foam rivets. This highlights the different parts and provides interest.</p><p>I painted the plastic chain with silver paint, though the paint began flaking off unfortunately. It does a great job of making the chain look real, and flaking off makes it look weathered. I cut the chain loops so I could easily hook and unhook the chain. The plastic is flexible enough to act like a clip. I looped a chain around each arm with a link in the back and two chains around the waist.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWlnN7bLL_Po6_9X9kBXRkOJkFDDpUwIWDCQhRdn4rilBDa1AL3Vftwq7bRJ4uSqqq5dZa6UjNNSA4mFBsRnlt3LMBcXyvsSJ7nDZc5iuvpMuxIQwo88KsMGKg4I8uGR4DAsDZ5YN4fbZuiQFUZJ7bDoUBKVLFqQU69yCFL4Ch8FwXSJqL6WMnGT0TZQU/s640/IMG_4860.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWlnN7bLL_Po6_9X9kBXRkOJkFDDpUwIWDCQhRdn4rilBDa1AL3Vftwq7bRJ4uSqqq5dZa6UjNNSA4mFBsRnlt3LMBcXyvsSJ7nDZc5iuvpMuxIQwo88KsMGKg4I8uGR4DAsDZ5YN4fbZuiQFUZJ7bDoUBKVLFqQU69yCFL4Ch8FwXSJqL6WMnGT0TZQU/s16000/IMG_4860.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Padlock and chain<br /></td></tr></tbody></table><p><span face=""arial" , "helvetica" , sans-serif"><b>Goat Hooves</b></span><br />I didn't want to use stilts for this costume, while the extra 16" of height looks cool and imposing the stilts are unwieldy. When I had the idea for goat hooves, I had to use the stilts, when else can I use goat hooves on a costume? </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgaq90v69Fe0lMhFgcNyO53iTOzo_Gi_yM-YVb8PIU9bfjUngwHLCDYNuhW5CYRoLTDS3B-mrZBROnJucjRRtFAxKez522rbkuBENzg0TBgyww6BFnADAIDLGpxg82MeojHtrtPexZNL0rhJwMDM_QoFbAjFj5tGlNjLq8VD4ODMV8nL_Ijpo1I_XVB7U/s640/IMG_4699.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgaq90v69Fe0lMhFgcNyO53iTOzo_Gi_yM-YVb8PIU9bfjUngwHLCDYNuhW5CYRoLTDS3B-mrZBROnJucjRRtFAxKez522rbkuBENzg0TBgyww6BFnADAIDLGpxg82MeojHtrtPexZNL0rhJwMDM_QoFbAjFj5tGlNjLq8VD4ODMV8nL_Ijpo1I_XVB7U/s16000/IMG_4699.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Goat hooves planning<br /></td></tr></tbody></table><p> </p><p>The hooves are EVA foam. It's glued around the stilts, but not to the stilts. I then glued the fur material to the top edge of the hoof, after painting the hooves. The fur is then hand stitched to the stilts to hold it in place. I didn't want hooves permanently attached to the stilts.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYMfyYlNTvmRsqVjBHlXJ83HOVGik5bP-kNMK2yN0x7mWmJ19JDDM6xP-5RC5nGAHlMY-Loa2tmGoLUo_TSYrc2Moc3tb7viefV0AA8XI0_P70ssRceC9EAJG6OGrmNpzklJ3AZNVBM785wjH4G_lJYwdphSDxN44-vvglsgqtB3kdqO1kiXsNc7vuaH4/s640/IMG_4849.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYMfyYlNTvmRsqVjBHlXJ83HOVGik5bP-kNMK2yN0x7mWmJ19JDDM6xP-5RC5nGAHlMY-Loa2tmGoLUo_TSYrc2Moc3tb7viefV0AA8XI0_P70ssRceC9EAJG6OGrmNpzklJ3AZNVBM785wjH4G_lJYwdphSDxN44-vvglsgqtB3kdqO1kiXsNc7vuaH4/s16000/IMG_4849.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Goat hooves final<br /></td></tr></tbody></table><p><span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span><br />
I really like this costume, but the stilts are really only for photo ops. In these stilts, one wrong step could lead to a very long fall. With the mask I lose all peripheral vision which makes that worse. With the hour glass and scythe my hands aren't free to catch myself if I fall. The stilts are cool, but difficult. I hoped I could use the scythe as a balance, and while it works it's only slightly less precarious.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQi9qBKR6gpQMFen9WABayMvoCDTeQkZylIq-YtxrEXVTekcEvHt5hktKAT_jumy01Kx0fwWeSyBatwfxJ3g-X5CtUwqt0sfotOS0P8wn2elD5RJ1hlg7yzaJDWh1JBWckhwmgeC7FS6Go2A5ISreWWbXM5lEDcv1LXUqJNJVV-uiKvQTxpGyETMM6WnY/s640/IMG_4833.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQi9qBKR6gpQMFen9WABayMvoCDTeQkZylIq-YtxrEXVTekcEvHt5hktKAT_jumy01Kx0fwWeSyBatwfxJ3g-X5CtUwqt0sfotOS0P8wn2elD5RJ1hlg7yzaJDWh1JBWckhwmgeC7FS6Go2A5ISreWWbXM5lEDcv1LXUqJNJVV-uiKvQTxpGyETMM6WnY/s16000/IMG_4833.jpg" /></a></div><p></p><p>Without the stilts things are much easier, though I didn't factor in how many places can't clear an 8' tall scythe. Most places I went, I couldn't hold it at full height due to the ceiling.</p><p>My only other complaints are making the neck of the robe and tabard too large as well as no opening in the robe to access pockets. </p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcVu09rjlnHBlHrxyDzKQ7htlbv9cz49Ex8TUM-mBJrBUOwsN1v5J5c0mwIdY6U0uvG-FsREcT6qlUYKPu1LAlBdfWOeVmnH_MpS298Al-lZYv4cOwkYlQrmaBB-90HLPF6TSSmQ_dX8nC22ReiaUh8QjCFyn9RlVRZeeHL8uo3-RSlhggCMMzDsmZz7k/s640/IMG_4865.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcVu09rjlnHBlHrxyDzKQ7htlbv9cz49Ex8TUM-mBJrBUOwsN1v5J5c0mwIdY6U0uvG-FsREcT6qlUYKPu1LAlBdfWOeVmnH_MpS298Al-lZYv4cOwkYlQrmaBB-90HLPF6TSSmQ_dX8nC22ReiaUh8QjCFyn9RlVRZeeHL8uo3-RSlhggCMMzDsmZz7k/s16000/IMG_4865.jpg" /></a></p><p>This year definitely set the bar for how unwieldy a costume can be, but it photographed really well. This is the first year I wasn't copying someone else's design, and that made things easier as I didn't have to mimic anything but also freed me to keep adding to the design. Because of that, this is going to be one of my favorites.<br /></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-6551469230585398592023-07-21T02:00:00.116-04:002023-07-27T17:22:53.729-04:00Compressor Cord Wrap<span face=""arial" , "helvetica" , sans-serif"><b>Metal Cord Wrap</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1pTJCrTxG2RaN_bzIP7APeiFXgP8cZqVtBEjEhSvBjOQzPfW0ljfLB9t8QQtdyRy1whMETVZ-XwtMUiJbaeJ8sT6sxtt5aFWiJ8VKbHWpuxFBmkEOIfHyFoyL1ikeW_OAv34d9mvnjjv2T7-5-szrCy9U2_K6C15wsiIRBU2Da10P9JcLEC7EWWkCfZg/s640/THUMBNAIL%20cord%20wrap.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1pTJCrTxG2RaN_bzIP7APeiFXgP8cZqVtBEjEhSvBjOQzPfW0ljfLB9t8QQtdyRy1whMETVZ-XwtMUiJbaeJ8sT6sxtt5aFWiJ8VKbHWpuxFBmkEOIfHyFoyL1ikeW_OAv34d9mvnjjv2T7-5-szrCy9U2_K6C15wsiIRBU2Da10P9JcLEC7EWWkCfZg/s16000/THUMBNAIL%20cord%20wrap.jpg" /></a><br />The cord for my portable compressor is always dragging the floor as I carry it. It's time to solve that problem.<br />
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<a name='more'></a><p>I considered wood, but that's too bulky. I had this metal strap from a ceiling fan. I also wanted the finished product to look factory because it should have been factory. If you want to skip the reading, and watch the tutorial, here you go:</p><p><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/afmYDAg5z_c" width="320" youtube-src-id="afmYDAg5z_c"></iframe><br /><br />
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<b>Purchase List:</b><br />Metal strap from my scrap pile. Final dimensions are 13" x 5/8" x 1/8"<br />You could buy metal or <a href="https://www.lowes.com/pd/Hillman-3-ft-x-0-75-in-Aluminum-Solid/3054619" target="_blank">aluminum flat bar</a> if you don't have scrap on hand<br /></p><div class="separator" style="clear: both; text-align: center;"></div><br /><div>
<b>Tool List:</b></div>
<div>Hack saw<br />Vice<br />Hammer<br />Cut off wheel<br />Grinder<br />Flat and circular files</div><div>Punch<br />Drill/ drill bit<br />Adjustable wrench<br /></div>
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<b>Cut List:</b></div>
<div>I had to cut the end off the metal strap<br /></div>
<div>It dimensions 1" / 2" 7" / 2" / 1" with 90* angles at each slash.<br /></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I would try to wrap the cord around the handle of the compressor, but it would never stay put. A cord wrap would solve that. I was able to use the bolts for the plastic cover as mounting points. The mounting points are cast into the motor. My first thought was two short brackets on each bolt, but that would be prone to rotating with only one mounting point. I also wanted this to look factory.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Bracket Building</b></span><br />With two bolts in the perfect spot, I looked through my scrap metal and found the perfect strap. I think it was part of a ceiling fan installation kit.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQJ15sjmVJ_-HoO-VSbBU2Or8XBrRkNHRFiwl1_Of3ZhM-fgGyIdi49Q_HcM9AVcLDxXYXRa9giKEjTHB-zn3KtoJkL0Nht2cv6DQpa42ISbmwkc2lebC0BKq0-zvPdBGgzwG54zrzBwIx9XYZQAuMhU5geWpnG7Aec-nEAwRBr9v0eOdBiIqIPCDRE88/s640/cord02.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQJ15sjmVJ_-HoO-VSbBU2Or8XBrRkNHRFiwl1_Of3ZhM-fgGyIdi49Q_HcM9AVcLDxXYXRa9giKEjTHB-zn3KtoJkL0Nht2cv6DQpa42ISbmwkc2lebC0BKq0-zvPdBGgzwG54zrzBwIx9XYZQAuMhU5geWpnG7Aec-nEAwRBr9v0eOdBiIqIPCDRE88/s16000/cord02.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHPGkpo5_3DJ92EQ9JwUCWzwBuIrjOKh3Hhz-W6zOOaXMkzhNNFf85F0yMWEW_pdA1ETkVGn0ksruqMbMLBTtECccLiliZCKnI5sCeMXKuXsli3diLVTmiRH474SeCPLOrEgbTqgpvgBRlo-WPpf1a4YTs18G9r_UzwCe3Q5Gk5eEbqq6uMLNfzj1KdOg/s640/cord04.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHPGkpo5_3DJ92EQ9JwUCWzwBuIrjOKh3Hhz-W6zOOaXMkzhNNFf85F0yMWEW_pdA1ETkVGn0ksruqMbMLBTtECccLiliZCKnI5sCeMXKuXsli3diLVTmiRH474SeCPLOrEgbTqgpvgBRlo-WPpf1a4YTs18G9r_UzwCe3Q5Gk5eEbqq6uMLNfzj1KdOg/s16000/cord04.jpg" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5a395Pc9JfRRUt36wwBcZ82hBdKCG50BPsAONTuhMz_gkEjNkzloSKUg0uNQJy-Rv7yKTBYdDk7FU8MFBVAP0564VhP378lJPafFFNZI4WhD-fqQOPimbf0LWolsvc0J-NKnXrYTdBZBm4r5VDZAO61jGvxFU4smC31gCNHgv8G1JDeBfknsQd5TGxDA/s640/cord05.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5a395Pc9JfRRUt36wwBcZ82hBdKCG50BPsAONTuhMz_gkEjNkzloSKUg0uNQJy-Rv7yKTBYdDk7FU8MFBVAP0564VhP378lJPafFFNZI4WhD-fqQOPimbf0LWolsvc0J-NKnXrYTdBZBm4r5VDZAO61jGvxFU4smC31gCNHgv8G1JDeBfknsQd5TGxDA/s16000/cord05.jpg" /></a>First I marked off the mounting holes. Since the heat sink is close on one side, I kept that extension short. I sized the existing bolts and drilled holes into the bar stock a size larger. Before drilling I used a punch to dimple the metal, otherwise your drill bit will walk and scratch the strap. A round file was used to remove any slivers of metal for a smooth finish. I used a vice to clamp the bar and a hammer to bend it 90*. Then I mounted it to size the length for the cord.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFoLYWeIwSlnEMGjngV5JiB1_eeZt7Q7oORKggwoKgUCYWDClp_X7LhKCnO_Vs5GNQ_R7h3-bgI2bgtz8K1-UrDQyOHgh1fpOVETEDT9jch068z727MWfYlWG3AJB1hIblOc9HFZi6SUv64veBnmA0G7iZPLTj_69DTSDuzAbMtSe9hDQroM-FbDq8HHI/s640/cord06.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFoLYWeIwSlnEMGjngV5JiB1_eeZt7Q7oORKggwoKgUCYWDClp_X7LhKCnO_Vs5GNQ_R7h3-bgI2bgtz8K1-UrDQyOHgh1fpOVETEDT9jch068z727MWfYlWG3AJB1hIblOc9HFZi6SUv64veBnmA0G7iZPLTj_69DTSDuzAbMtSe9hDQroM-FbDq8HHI/s16000/cord06.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEbrGTrdI3jsq_-mWl562cp0zvx5Zf6_xqgOQjQjy8kqkkPFLXdy24YAGBIQ3lUefXEs4MNNYVdaD1vtPlxzVmYqiARqSrgirPZOgJUKJA7-jMYpsz0ZQfY8waU8C5gqUNWPytSGj8mu4jRkFxmxSvHi-ZTAsN77l6ViE_Y_gKn-3GM6N3BcbLi9rzg5M/s640/cord07.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEbrGTrdI3jsq_-mWl562cp0zvx5Zf6_xqgOQjQjy8kqkkPFLXdy24YAGBIQ3lUefXEs4MNNYVdaD1vtPlxzVmYqiARqSrgirPZOgJUKJA7-jMYpsz0ZQfY8waU8C5gqUNWPytSGj8mu4jRkFxmxSvHi-ZTAsN77l6ViE_Y_gKn-3GM6N3BcbLi9rzg5M/s16000/cord07.jpg" /></a>I settled on 2" of length for the cord space. I wanted to keep this as compact as possible, but I also wanted to have enough room for the cord to loosely wrap. For reference, my cord is 72" long. You would need to adjust that 2" length based on length of cord. I determined 1" would hold the cord in place.</p><p>I placed the strap in the vice and bent the strap again on each side. I used a cut off wheel to cut off excess length, and then a grinder to shape it. Giving the ends a rounded shape makes this look like a retail piece instead of a piece of scrap hacked together. I finished the shape with a flat file to make sure there were no rough or sharp edges.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwJRcFyNFZb6ywGx7mTMO2J4i6hMGkbqMGKPBgxBC4JzQNyKr0cbBowIOoj3JXIO9LRPHlCuwFIyii5HeM7-3yiiiQD_nZ4OMmG_Zmzs7xJrJe2mDbip8KFLebSQR6eBclTxdTAI_mKCPiQHebNJ1vonfuWpLSK8lGxSEQAu3QhF-W188i4LwAjRLqd4I/s640/cord08.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwJRcFyNFZb6ywGx7mTMO2J4i6hMGkbqMGKPBgxBC4JzQNyKr0cbBowIOoj3JXIO9LRPHlCuwFIyii5HeM7-3yiiiQD_nZ4OMmG_Zmzs7xJrJe2mDbip8KFLebSQR6eBclTxdTAI_mKCPiQHebNJ1vonfuWpLSK8lGxSEQAu3QhF-W188i4LwAjRLqd4I/s16000/cord08.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcKLh3ey9gUvEGZPfACUKXi0h2MosgZ1lXQY1bYOrwk6DCmggeqClH1FRYbjIWjkkKGDQyePfeACu3kIjcH7PYN7-tYrC1GrF8ygX8oJWZs8sgKvuvq_zPLMaFVPx3XaSbxNOsFLa-iUoLGqGdj4XSebg5SxlotKeN1XyFlmbYbxbv0bZxr4CRXQZGYPg/s640/cord09.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcKLh3ey9gUvEGZPfACUKXi0h2MosgZ1lXQY1bYOrwk6DCmggeqClH1FRYbjIWjkkKGDQyePfeACu3kIjcH7PYN7-tYrC1GrF8ygX8oJWZs8sgKvuvq_zPLMaFVPx3XaSbxNOsFLa-iUoLGqGdj4XSebg5SxlotKeN1XyFlmbYbxbv0bZxr4CRXQZGYPg/s16000/cord09.jpg" /></a>I realized one of my mounting holes was 1/16" off and I could get both bolts back in. I used a round file to enlarge the bolt hole just enough. It helps to mark it in pencil so you don't have to test fit as often.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Finish</b></span><br />Once the wrap was mounted in place, it didn't require any finishing. The cord wrap is the perfect size, allowing me to easily wrap the cord and tuck the end. It looks like the cord wrap came on the compressor from the factory which was the desired look. Functional and factory looking was always the end goal.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFHXzsESmHTnDdENxodvtAfTzgAiBg7MGR-EFaU_0bKWXMFpAH9plbcxIUVMo8oYOwbhrGzQvXYskCHwUnecnyeig6Nf7BBa3PtN6mYMdv8VOfZFDLmpEzWr_8R8-4h6LigBn5AmQc8Q2n6sfZvsbN-9GEv7CrQ-KxKnwiNoFArNWf8n6hFbsqH5CHYsA/s640/cord11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFHXzsESmHTnDdENxodvtAfTzgAiBg7MGR-EFaU_0bKWXMFpAH9plbcxIUVMo8oYOwbhrGzQvXYskCHwUnecnyeig6Nf7BBa3PtN6mYMdv8VOfZFDLmpEzWr_8R8-4h6LigBn5AmQc8Q2n6sfZvsbN-9GEv7CrQ-KxKnwiNoFArNWf8n6hFbsqH5CHYsA/s16000/cord11.jpg" /></a></div>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-26613957449319365832022-12-09T02:00:00.210-05:002022-12-09T02:00:00.194-05:00Install an Exterior Receptacle<span face=""arial" , "helvetica" , sans-serif"><b>An Outlet for the Outside</b></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPp0pyuC8lUDv9NDsyK5KmD_uWxcnmO9aJPT_KbUuaMAAMGZJ4qgtW5Wz1Ed3JkQ83MHezreVX5nJza8gdANKfdLpS97xoJmKKmMFfAyKTxcn0joKGs4NLlxasJ_JkPuMK4X_VdsNvNV6TYjl5fDHvXeHXqkNi6X8_zNJszEFBX7bI3S_HTz5xYnL8/s640/THUMBNAIL%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPp0pyuC8lUDv9NDsyK5KmD_uWxcnmO9aJPT_KbUuaMAAMGZJ4qgtW5Wz1Ed3JkQ83MHezreVX5nJza8gdANKfdLpS97xoJmKKmMFfAyKTxcn0joKGs4NLlxasJ_JkPuMK4X_VdsNvNV6TYjl5fDHvXeHXqkNi6X8_zNJszEFBX7bI3S_HTz5xYnL8/s16000/THUMBNAIL%20copy.jpg" /></a><br />
My house didn't have an exterior receptacle on the front. It really needed one.<br />
<a name='more'></a><br />I don't know why I hadn't installed a receptacle earlier. I think it's one of those early faults of the house that I just accepted and forgot about. With Christmas and the desire for Christmas lights, I was prompted to install a receptacle. My initial thought was to tie into an interior receptacle. After a bit of online research, my plan was confirmed.<br />
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<b>Purchase List:</b><br />
<div><a href="https://www.lowes.com/pd/TayMac-1-Gang-Rectangle-Plastic-Electrical-Box-Cover/999968881" target="_blank">one gang GFCI receptacle, box, and cover</a><br /></div>
<div><a href="https://www.lowes.com/pd/Romex-SIMpull-25-ft-12-2-Non-Metallic-Wire-By-the-Roll/1098043" target="_blank">12/2 Electrical wire</a><br /></div>
<div><a href="https://www.harborfreight.com/4-piece-anti-fatigue-foam-mat-set-94635.html" target="_blank">EVA foam for a gasket</a></div><div><a href="https://www.lowes.com/pd/Sigma-Electric-ProConnex-3-4-in-Clamp-on-Type-Service-Entrance-Connector-Conduit-Fitting/1087283" target="_blank">3/4" Strain relief clamp</a></div><div><a href="https://www.lowes.com/pd/Cobra-100-Pack-1-1-4-in-x-1-4-in-Dia-Standard-Drywall-Anchor-Screws-Included/3029073" target="_blank">Plastic anchors</a> <br /></div><div><a href="https://www.lowes.com/pd/DAP-3-lb-Premixed-Finishing-Drywall-Joint-Compound/3043313" target="_blank">drywall compound </a></div><div><a href="https://www.lowes.com/pd/Gold-Bond-1-2-in-x-4-ft-x-8-ft-High-Strength-LITE-Drywall-Panel/5001486207" target="_blank">1/2" drywall </a></div><div>steel wool </div><div>wire nut<br /></div>
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<b>Subtotal: $130 (starting with nothing)</b></div><div>I only spent $35 as I already had everything but the receptacle/box/cover<br /></div>
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<b>Tool List:</b></div>
<div>3/8" masonry drill bit for drilling through the brick for the wire<br /></div><div>1/4" masonry drill bit for mounting the box<br />1/2"x12" or longer drill bit</div><div>Drill</div><div>Receptacle test light <br /></div><div>1/4" metal rod, preferably with hole in the end. I had a piece of scrap <br />14 gauge wire</div><div>duct tape<br /></div><div>Wire strippers</div><div>Flashlight to see into wall</div><div>hobby knife to cut an access hole<br /></div>
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</div><p><span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />This needs to be a GFCI receptacle. Any receptacle that could be prone to water such as outdoors, bathrooms, or near a kitchen sink needs to be GFCI.<br />I only had one receptacle that was easily accessible on the front of the house and on the side I wanted it. By removing the cover plate I could tell which side of the stud the receptacle box was mounted. I also determined there was a jack and king stud at the nearby window. This offered a roughly 14" cavity, but I wanted the exterior outlet as close to the interior outlet to make fishing wire through the wall easier.<br />I used the window sill as a height reference, transferring the interior measurements to the outside. I wanted to stay above finish floor as I wasn't sure how much space was between the brick and rim joist and whether I could snake wire through.<br /></p><p>Before beginning I made sure the breaker for this circuit in this room was off and double checked with a test light.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSU7iDGIKfU-2ETDpsPbszW81mhpocDRnbfPC6xLJLwwpAO2fM0VtZLXaCTDvKAIwmAZZrhTlc2HnpBrjXE-xpfXMDsbIpT_QNrLkK-e3RIrSpa5E3DqH5z59worNXg4ml2BtAGUjbbVU81GXasLBP1zJvu06ZZ_W_G3FqjqPB2UV2vnoCPkkGrTsG/s640/09%20Exterior%20Receptacle.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSU7iDGIKfU-2ETDpsPbszW81mhpocDRnbfPC6xLJLwwpAO2fM0VtZLXaCTDvKAIwmAZZrhTlc2HnpBrjXE-xpfXMDsbIpT_QNrLkK-e3RIrSpa5E3DqH5z59worNXg4ml2BtAGUjbbVU81GXasLBP1zJvu06ZZ_W_G3FqjqPB2UV2vnoCPkkGrTsG/s16000/09%20Exterior%20Receptacle.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Blue is the interior receptacle, gray is the future exterior receptacle<br /></td></tr></tbody></table><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2hrKNI8kLgbScIwi7VdOwW8IDvhQlWUkBkKwuR9k3m5VxsbZyWKfu540fLowPfJbZe_jjl_kX5e5ZhTR_ZoMFdtqTcdXWsRlKleK47GxaS4RXrq7kfVSUTQArDKr5tM142Cud2Y390hrqJjcTXQn7ELD0DrSbPI3JUDzr0YEWtP9vofp7HzxE4Lx-/s640/IMG_0845.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2hrKNI8kLgbScIwi7VdOwW8IDvhQlWUkBkKwuR9k3m5VxsbZyWKfu540fLowPfJbZe_jjl_kX5e5ZhTR_ZoMFdtqTcdXWsRlKleK47GxaS4RXrq7kfVSUTQArDKr5tM142Cud2Y390hrqJjcTXQn7ELD0DrSbPI3JUDzr0YEWtP9vofp7HzxE4Lx-/s16000/IMG_0845.jpg" /></a><br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Exterior Hole</b></span><br />Using the measurements I had previously determined, I marked the exterior hole. I double checked my measurements, and thankfully the height from the ground was perfect. I drilled through the mortar as it's typically softer than brick and thus easier to drill through.<br />I drilled the holes right next to each other, then used a hammer and screwdriver to knock out the little bit of mortar between the two holes. If you have to leave it overnight, like I did, a bit of steel wool will keep bugs seeking warmth out.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAau-jDPHKfBsA3-G8OILJQK82uAh_Jpb0UOyrCNE22sKlbinQ-K8qzA_1CUZQDJ7ElBPZqWfKeTgtUMyo2mJDfefAI22a2ndk-UlF1u733idIzuo6csOmD-2GdOLFn_XBCPo2VCThlkJZwwjyox6NsS47Kp29q4wGvl5s6-TdIZrDBP1yPnkrFFsT/s640/IMG_0863.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAau-jDPHKfBsA3-G8OILJQK82uAh_Jpb0UOyrCNE22sKlbinQ-K8qzA_1CUZQDJ7ElBPZqWfKeTgtUMyo2mJDfefAI22a2ndk-UlF1u733idIzuo6csOmD-2GdOLFn_XBCPo2VCThlkJZwwjyox6NsS47Kp29q4wGvl5s6-TdIZrDBP1yPnkrFFsT/s16000/IMG_0863.jpg" /></a><br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Interior Access</b></span><br />I cut a 1" square hole below the receptacle box with a hobby knife. Being on the bottom would make a less than perfect repair less visible. Using the thickness of the wall at the window, I determined the wall was 9" thick, I used that dimension and how much lower the outside box would be for a rough idea of the angle I need to drill through the wall at the access hole.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFPc_n1EnsFMpmIOxeR3Wbmsg9UUN16la5NVJJI3V_p6_X9tfX8IT83tRvJW8vPzqJxjhHPN5W-_-Os4FzHvxzjEgUbLzsOzPVA14kOeCoFtBUT113j9jp-YAxmIZMxV1p_rD_V7bcqTGIejDT9mcG9Eapx0lF5aPdxn_gHTMuaBE9yIrjGwEh29KY/s460/IMG_0899.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="345" data-original-width="460" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFPc_n1EnsFMpmIOxeR3Wbmsg9UUN16la5NVJJI3V_p6_X9tfX8IT83tRvJW8vPzqJxjhHPN5W-_-Os4FzHvxzjEgUbLzsOzPVA14kOeCoFtBUT113j9jp-YAxmIZMxV1p_rD_V7bcqTGIejDT9mcG9Eapx0lF5aPdxn_gHTMuaBE9yIrjGwEh29KY/s16000/IMG_0899.jpg" /></a><br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Running Wire</b></span><br />I had scrap metal rod with a hole in the end. Through trial and error I ran it through the stud cavity, through the sheathing, and after a few minutes finally managed to see it from the outside. This took quite a while. I thought I might have drilled the inside hole too high. The is definitely easier as a two person job, if not mandatory. Once I could see the end of the rod I created a hook from scrap 14 gauge wire to hook the end of the rod. I then taped the scrap 14 gauge wire to my 12/2 Romex wire and attempted to snake the wire through the wall.</p><p>This was a frustrating process. I thought I might need to drill the outside hole larger or create a larger interior access opening. At first I thought the sheathing might be the problem, but from what I could see through the opening it wasn't the issue. After trial and error I tried using a small metal rod beside the Romex wire and pushing them both through the opening from the outside. This worked well, I would push a few inches in, then pull it from the inside and repeat the process. I think the issue is that pushing from the outside the wire was bending while in the brick and getting caught. From the inside it was getting caught on the inside edge of the brick.Also the extra thickness of tape and scrap 14 gauge wire didn't help.<br />
<b><br />Wiring the GFCI Receptacle</b><span face=""arial" , "helvetica" , sans-serif"><b></b></span><br />
I screwed in the strain relief from the inside, which makes the clamping screws almost impossible to tighten, but it blocks the hole and I don't want bugs trying to get into my house. I also stuff steel wool into the hole I drilled through the brick.</p><p>I cut EVA foam to act as a gasket, tracing the box onto the foam and making the gasket 1/2" wide. While you would typically caulk around the box, since brick is an uneven surface, foam will act as a gasket and cleaner finish. <br /></p><p>The GFCI receptacle has a LOAD and LINE slot on the back. The wire from the interior should feed into the LINE slot. If you were going to install a receptacle downstream, it would be fed from the LOAD slot.</p><p>The black and white wires are installed with screw down clamps on the receptacle. Strip them first. The box and receptacle are grounded which requires a wire nut for the receptacle, box, and incoming line.</p><p>Bend the wire in the box into a Z shape so it will fold into the box. From there I pulled the slack out of the 12/2 wire from the inside.</p><p>I marked the box mounting points of the box onto the brick using a hammer and nail. While a hammer drill is ideal, a regular drill can work. I would push on the drill every few seconds to hasten the work. Hammer the plastic anchors into the holes and screw in the box. The box has a pull out clip so that a cord can be plugged in and the cover still shut.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjwZOuDaxQ3Vs60TJwGX0cSxwFuib4PeHXjFUd069c9q0qqKGgddFMBOCPRjrXrdFTFRZhBf4e4v8uTHP9ICHpNwV1YrT0GAR_shU8IHr65-w_SBmVAHmVJGSv5w-AOMIWRFHZEdOE6dMuBPfoFStRUKPkEombAQy0QqiRmrQ0UPf204k8JpC_HvgG/s640/64646A91-624D-41AA-9CA1-4CE4D85BCA98.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjwZOuDaxQ3Vs60TJwGX0cSxwFuib4PeHXjFUd069c9q0qqKGgddFMBOCPRjrXrdFTFRZhBf4e4v8uTHP9ICHpNwV1YrT0GAR_shU8IHr65-w_SBmVAHmVJGSv5w-AOMIWRFHZEdOE6dMuBPfoFStRUKPkEombAQy0QqiRmrQ0UPf204k8JpC_HvgG/s16000/64646A91-624D-41AA-9CA1-4CE4D85BCA98.JPG" /></a></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Wiring to the Interior Receptacle</b></span><br />
With pliers and much frustration I managed to pull the other end of the wire into the existing receptacle box. To do this I pushed all of the wire back into the wall, keeping the end close to feed it into the box. I made a service loop just outside of the box, with roughly 6" of slack in the 12/2 wire. I then cut the excess, stripped the wires, and inserted them into the existing receptacle.</p><p>I was able to double wire the ground screw and reinstalled the receptacle.<br /></p><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Power On</b></span><br />After I checked everything was secure and installed correctly I turned the breaker on. The 'Reset' button on the GFCI receptacle will need to be pushed to activate the receptacle. Pushing test will de-activate. If the receptacle grounds out, the 'Reset' will need to be pushed to activate the receptacle again.<br /></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Drywall Finishing</b></span><br />After all the work, my access hole was in rough shape. I re-cut it to make it square and then cut a drywall patch. I cut it larger so I'd have a 1/4" paper overlap onto the existing wall. This way there's not an open joint you're trying to fill.I caulked this piece in place, then used drywall compound to feather the patch.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXv5-cO7bMyaaoMk_mTjel1AAbVeeORnQkHRDQNq4I7kp3dRiEruWkXdD61KDyr2iXjhTbTYaEFO27FKeKSrI1INwq0ul5ydBFR-J6PrgX1Teb7Ws-CaIqg4q78R2tyDuVn872F8WVRO18BdSEMCBtp1fk_T9Am5pBOShj7_Ml0is0-7X54apNDxFg/s460/IMG_0907.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="345" data-original-width="460" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXv5-cO7bMyaaoMk_mTjel1AAbVeeORnQkHRDQNq4I7kp3dRiEruWkXdD61KDyr2iXjhTbTYaEFO27FKeKSrI1INwq0ul5ydBFR-J6PrgX1Teb7Ws-CaIqg4q78R2tyDuVn872F8WVRO18BdSEMCBtp1fk_T9Am5pBOShj7_Ml0is0-7X54apNDxFg/s16000/IMG_0907.jpg" /></a> <br /></p><p>Defying expectations, I somehow already had matching paint to complete the repair.<br /></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span><br />Running the wire was the most frustrating part as I expected. I'm glad I decided to use a metal rod to push the wire into the wall. Finally there is receptacle access on the front of the house. With it being Christmas, this receptacle was put to immediate use.<br /></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-62887488223700890852022-07-29T02:00:00.287-04:002022-08-27T09:25:05.826-04:00Build a Computer<span face=""arial" , "helvetica" , sans-serif"><b>Build Your Own Computer</b></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqhZRAQO3QGQvQ7KDYVYFsEdqQtQtP67TcnY5-rlL1sSNfjOK0L7jWlHivlu6QHEbp77SgMDrIoJ51F2JtARiilRE96mRVgbzaGJUFQEs82aptlbUVBSjCaWK5dI768YC6x_bRMxuP0bUK8CbtPr3tJ2dt6k2yef2z2e-98XcKNXqzXJRg0Achhoeu/s640/covercomputer.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqhZRAQO3QGQvQ7KDYVYFsEdqQtQtP67TcnY5-rlL1sSNfjOK0L7jWlHivlu6QHEbp77SgMDrIoJ51F2JtARiilRE96mRVgbzaGJUFQEs82aptlbUVBSjCaWK5dI768YC6x_bRMxuP0bUK8CbtPr3tJ2dt6k2yef2z2e-98XcKNXqzXJRg0Achhoeu/s16000/covercomputer.jpg" /></a><br />
<br />I've always wanted to build a computer, I just hadn't had the opportunity.<br />
<a name='more'></a><p><br />I cobbled my son's former computer together with what I had around. The power supply was going out, so we opted to build a new computer, reusing a few components.</p><p>I had replaced memory, hard drives, and graphics cards. I had never built a computer from scratch. The first step was research to understand what components were 'good,' what fit together and how, and just general information about this process.</p><p>Overall it went smoothly. I was certain I'd be missing a cord, cable, or some other vital component during the build but that wasn't the case. I built the computer in an afternoon and spent another day just trying to get a Windows OS going. Installing the OS was the most difficult part. <a href="https://www.youtube.com/watch?v=affB8PNiuHY" target="_blank">Watch the video</a> if you want to skip the read.<br /></p><p>This is definitely a budget build. A build can quickly go over budget. I saved by reusing the graphics card and hard drives.<br />
<br />
<b>Purchase List:</b><br />-Case: Thermaltake Versa H18 with Tempered Glass $55<br />-Power supply: Corsair CX750M 80 Plus Bronze $80<br />-Motherboard: MSI MAG B560M Bazooka $160<br />-Processor: Intel Core i5 $154 (Amazon Lightning deal)<br />-Processor cooler: ID-Cooling CPU Air Cooler 120mm $24<br />-Memory: Silicon Power 16GB (8GBx2) $50<br />-(2) Case Fans: Arctic P14 140 mm $13 each<br />-PC LED Flexible Light Strip $9 <br />-Hard drive: Reused PS3 500 GB (new $70-$100 for a HDD or SSD) <br />-Graphics cards : Reused GTX 760 ($100 from eBay or $300 for a new card)<b><br /></b>-Operating system: Windows 10 ($100 if you don't have a license)<br />-Reused monitors, mouse, keyboard, speakers<br /><b>Subtotal: $658 </b>easily $1100 if all parts were purchased new. Even more if you have to purchase peripherals<br /></p>
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<b>Tool List:</b></div>
<div>screw driver with a small phillips bit<br />scissor<br /></div>
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</div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />Before making any purchases I checked to make sure components were compatible. The crucial information to confirm is that the processor and motherboard will work together. This will be listed on the product page of the motherboard. I researched other builds on the internet that used similar components prior to even considering making a purchase just to understand terms and components. After looking at a few builds, you begin to see commonly used components and terms.</p><p>If you waited for deals and discounts you could save more. I managed to get $50 off the processor on a Lighting deal.<br /></p><p>Since this was my first attempt at building a computer, I read all of the product instructions to make sure I wasn't missing anything. Most of the instructions were really good. The power supply documents were lacking.<br /></p><p><b>Components</b><br /></p><table cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: right;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEucZzCYpwpZjsraznCJaiwXxIY9ZEkYgBgbJ9F799YcivhYBqd-29CUmBJw6rGlVMlidZKIm37DXwZp4ieRf3pgCrD-OVcZoz-2Zmy9bKNtjwSBv1JLPPOzqUT05CHA6FreW8UxizeFtxdo-83t8virEF0OgsU7nFHOfa3vCR5OJMXDNdlB759V1q/s640/Capture1.PNG" style="clear: right; margin-bottom: 1em; margin-left: auto; margin-right: auto;"><img border="0" data-original-height="626" data-original-width="640" height="313" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEucZzCYpwpZjsraznCJaiwXxIY9ZEkYgBgbJ9F799YcivhYBqd-29CUmBJw6rGlVMlidZKIm37DXwZp4ieRf3pgCrD-OVcZoz-2Zmy9bKNtjwSBv1JLPPOzqUT05CHA6FreW8UxizeFtxdo-83t8virEF0OgsU7nFHOfa3vCR5OJMXDNdlB759V1q/s320/Capture1.PNG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Case: Side<br /></td></tr></tbody></table><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="float: left; margin-right: 1em; text-align: left;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGeRTh5fJFLQDfuf-UnoqDs_AWbZ6p1NO_g2Oo_iCHVr7rsRtdcBNSsRkKB35XkZIMwZN6xtmb7y9spixX1rN5l0zc3FBuUE_0BjUictE-yaTlnI9yU2lnmsW5zDuFQrluFFkvf3-mIsPwXxjP-5G_po9FJcz7AKPoj_X6lTZAglcpeImJVRe1I-Te/s760/Screenshot%202022-07-25%20at%2015-07-49%20Amazon.com%20Thermaltake%20Versa%20H18%20Tempered%20Glass%20Black%20Spcc%20Micro%20ATX%20Gaming%20Computer%20Case%20CA-1J4-00S1WN-01%20Everything%20Else.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="760" data-original-width="640" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGeRTh5fJFLQDfuf-UnoqDs_AWbZ6p1NO_g2Oo_iCHVr7rsRtdcBNSsRkKB35XkZIMwZN6xtmb7y9spixX1rN5l0zc3FBuUE_0BjUictE-yaTlnI9yU2lnmsW5zDuFQrluFFkvf3-mIsPwXxjP-5G_po9FJcz7AKPoj_X6lTZAglcpeImJVRe1I-Te/s320/Screenshot%202022-07-25%20at%2015-07-49%20Amazon.com%20Thermaltake%20Versa%20H18%20Tempered%20Glass%20Black%20Spcc%20Micro%20ATX%20Gaming%20Computer%20Case%20CA-1J4-00S1WN-01%20Everything%20Else.png" width="269" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Case: Front<br /></td></tr></tbody></table><br />
<br />
<p></p><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihpELmTHrQQgUwH2wEAHuXPaHv8Y3rAiSRnrGcXmqH7QaQ5IDVmbrwrdvsLhIVjKHM--jTM4eUbUYAbnBBW6HYKrRn6L6DOMMwnEiP3CQMX9uJxG2dmej_ScuULNKy-QBpk2ycE-qZVPFHByHRm7pcreUWlRlskbOvWNmZ5nqEVoKw9V7_x1cLqBnp/s640/Screenshot%202022-07-25%20at%2015-06-50%20MSI%20MAG%20B560M%20BAZOOKA%20LGA%201200%20Micro%20ATX%20Intel%20Motherboard%20-%20Newegg.com.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="618" data-original-width="640" height="309" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihpELmTHrQQgUwH2wEAHuXPaHv8Y3rAiSRnrGcXmqH7QaQ5IDVmbrwrdvsLhIVjKHM--jTM4eUbUYAbnBBW6HYKrRn6L6DOMMwnEiP3CQMX9uJxG2dmej_ScuULNKy-QBpk2ycE-qZVPFHByHRm7pcreUWlRlskbOvWNmZ5nqEVoKw9V7_x1cLqBnp/s320/Screenshot%202022-07-25%20at%2015-06-50%20MSI%20MAG%20B560M%20BAZOOKA%20LGA%201200%20Micro%20ATX%20Intel%20Motherboard%20-%20Newegg.com.png" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Motherboard</td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHJNZVLtQjpI1vV94Mva-Btz7VWWDEcS0SbMIc2dCTHzr20a9G8onsz-fdM3BvvMLT3ikr8fH5YoNVnjX31fol8GA9zFmnFO0IH26GUtKjc3xSUBWdAaIUaqlcK0g0bn583OAkTz1DAK6HcCqf0q7aSM-r_raK8Ic5rnDdLo8dWEI7ndyXElvDijnk/s320/Capture.PNG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="274" data-original-width="320" height="274" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHJNZVLtQjpI1vV94Mva-Btz7VWWDEcS0SbMIc2dCTHzr20a9G8onsz-fdM3BvvMLT3ikr8fH5YoNVnjX31fol8GA9zFmnFO0IH26GUtKjc3xSUBWdAaIUaqlcK0g0bn583OAkTz1DAK6HcCqf0q7aSM-r_raK8Ic5rnDdLo8dWEI7ndyXElvDijnk/s1600/Capture.PNG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Processor</td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBbmKyKiGr03b9KfBmcfhjHc7lKskC-iCc1NvT1_T5a3vh0IDKgBwOmq4X605T61lH9qNkJSNHW7XdiNe0PYiU2iFetTSH0RtJyaMyuMB-cb1AcvQ6txeNYP5qFyogzSTaoPwkOPjnzdSWLMtS7D260Kp4OVm-kZFUAVJp-dk1ppZ3thEIUDibzydn/s640/Capture5.PNG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="504" data-original-width="640" height="252" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBbmKyKiGr03b9KfBmcfhjHc7lKskC-iCc1NvT1_T5a3vh0IDKgBwOmq4X605T61lH9qNkJSNHW7XdiNe0PYiU2iFetTSH0RtJyaMyuMB-cb1AcvQ6txeNYP5qFyogzSTaoPwkOPjnzdSWLMtS7D260Kp4OVm-kZFUAVJp-dk1ppZ3thEIUDibzydn/s320/Capture5.PNG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Memory</td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidYrCWKKyO_l9nhLiS3nYa4SDTQioifcxhUvreT4jLtUELQ7MzZfAlclNEpzVGr0var7h6c7xOBl30D-a_yiANd60hAaDdCKWkiJfRwiIR5I9BIc2D0f7K19X_tI8rEmGBNLmMYxZjK9XzfMm0_B4g7OWV-O-P6qAAsftpEYPi18mVrC_NEarqyhD7/s683/Capture2.PNG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="503" data-original-width="683" height="236" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidYrCWKKyO_l9nhLiS3nYa4SDTQioifcxhUvreT4jLtUELQ7MzZfAlclNEpzVGr0var7h6c7xOBl30D-a_yiANd60hAaDdCKWkiJfRwiIR5I9BIc2D0f7K19X_tI8rEmGBNLmMYxZjK9XzfMm0_B4g7OWV-O-P6qAAsftpEYPi18mVrC_NEarqyhD7/s320/Capture2.PNG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Power supply<br /></td></tr></tbody></table><p><br /><span face=""arial" , "helvetica" , sans-serif"><b>Motherboard Assembly</b></span><br />The
only motherboards I had handled before came from pre-built computers
like Dell, HP, Lenovo. This motherboard was much beefier, with large
heat sinks and clear labeling of ports. </p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSf9JdRU79PMF_e09DNbpVD_3PcLBdLxXgQxfo9kZiI2lx6fJUWBGdpuE6sDE0d2TJFAOfiMgwQBNbOlS2UI-2l9yF1Mk6ZVdKmVmv3l88PZDaJREoxSxR_gqUnn9EdA1vnaZZGVwvRGDhp7szuhIe67JFnz7BuVIQu2imwkReZQ-bH8VBdOTcxgbr/s640/Screenshot%202022-07-25%20at%2015-06-50%20MSI%20MAG%20B560M%20BAZOOKA%20LGA%201200%20Micro%20ATX%20Intel%20Motherboard%20-%20Newegg.com%20copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="618" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSf9JdRU79PMF_e09DNbpVD_3PcLBdLxXgQxfo9kZiI2lx6fJUWBGdpuE6sDE0d2TJFAOfiMgwQBNbOlS2UI-2l9yF1Mk6ZVdKmVmv3l88PZDaJREoxSxR_gqUnn9EdA1vnaZZGVwvRGDhp7szuhIe67JFnz7BuVIQu2imwkReZQ-bH8VBdOTcxgbr/s16000/Screenshot%202022-07-25%20at%2015-06-50%20MSI%20MAG%20B560M%20BAZOOKA%20LGA%201200%20Micro%20ATX%20Intel%20Motherboard%20-%20Newegg.com%20copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">1. Accessory ports<br />2. Processor power connector<br />3. Processor/CPU socket<br />4. PCI-E Graphics card slot<br />5. Memory slots<br />6. Motherboard main power connector<br />7. Sata hard drive ports<br /></td></tr></tbody></table>The first step was seating the processor to the motherboard. I was concerned about messing this up. The processor has an arrow in one corner that will match to an arrow on the motherboard. I used an LGA processor which is Land Grid Assembly. The pins are on the motherboard, not the processor. Since pins are the most likely part to get damaged, the cheaper part has the pins.<br />I made sure to seat the processor perfectly. There is a metal clamp assembly that has to be opened to set the processor. Also, you'll need to pop out the plastic protective cover. Once the processor is seated, you clamp it in with the metal assembly. This part made me nervous as it takes a bit of force.<p></p><p>Then I had to apply thermal grease to the processor. Grease came with the cooler. The instructions are pea or rice grain size. Don't spread it, the pressure of the heat sink will do that. Before applying the grease I installed the backing plate for the heat sink. The cooler came with all of the necessary screws, brackets, and stand offs. I installed a backer plate, standoffs, then brackets. Once the brackets were in place, I applied the grease, gently put the heat sink on top, centered, and screwed it down. You should NOT see grease seep out from the edges of the processor. If so, take off the heat sink, clean it up and reapply less. Pea size worked for me.</p><p>The heat sink fan clamps to the sink with brackets. I positioned the fan, which has arrows indicating direction, to push air to the rear case fan through the heat sink. This is the typical orientation per Google.<br /></p><p>I installed the memory which must go in certain slots, see the instruction manual. Make sure the clips on both ends of the memory slots are open. They should snap closed as you install the memory.<br /></p><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Case Assembly</b></span><br />I really liked the case. It's nicely designed with a lot of features like numerous spots for zip ties, customization in fan placement, and the case is designed to hide wires for a clean look since one of the side panels is glass.<br /><br />The case included all of the standoffs and screws for the motherboard. At this point I installed the motherboard into the case. I just did the screws tight enough. Once I felt any resistance I quit tightening.</p><p>The motherboard comes with a trim plate that clips into the back of the case prior to the motherboard install for the various rear ports.<br /></p><p>With the motherboard in place, I installed the cables for the front face of the case. This includes, power switch, lights, audio, and USB ports. <br /></p><p>The case has a spot for fans at the front and top. A fan comes preinstalled in the back. My fans were too deep for the top mount, blocked by the motherboard heat sink. I installed both in the front of the case. While the instructions show mounting the front fans outside of the case behind the face plate, they were too deep. I installed them inboard of the front of the case. The fans came with screws. The case is slotted to mount the fans higher or lower. The 4 pin connections attach to the motherboard. All of the ports are labeled on the board and detailed in the manual.<br /></p><p>The power supply installs at the back bottom. It comes with screws. A 24 pin connector connects to the motherboard while an 8 pin connector provides power to the processor.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Power Supply Installation</b></span><br />It's a modular power supply, which means the cords can be detached completely aside from the motherboard and processor power connections. The power supply doesn't have any instructions. It has many cables, but I picked out the cables for the graphics card and hard drives. There's also a connection for the Molex connector for the LED at the front of the case. This can be daisy chained for the magnetic LED lights inside the case.</p><p><b>Test One</b><br />With all of this done I cut on the system. Nothing happened. I then removed the power supply and jumped pins 4 &5 to test it. The fan came on which means the power supply is good. I reinstalled the power supply and tried again. Success. I'm thinking maybe I didn't have the 24 pin connector fully engaged. Switching on the computer at this point opens the BIOS. The computer can't boot as there is no OS.<br /></p><p><b>Operating System Installation<br /></b>I was reusing hard drives and assumed the computer could boot the OS from the old hard drive. That's not the case for whatever reason. I tried different hard drives, different port orders, etc but the computer could never pick up the OS. Apparently a new motherboard likes a fresh Windows install.<br /></p><p>I had another hard drive I reformatted. I used an external hard drive connector to attached it to another computer, right clicked on it, and formatted it. Choose NTFS file type. Since this was a PS3 hard drive I deleted the existing partitions before formatting.<br /></p><p>I then downloaded the <a href="https://www.microsoft.com/en-us/software-download/windows10" target="_blank">Windows 10 installation media</a>. You need to double click this file to install it on the USB. I copied and pasted it on the USB the first time which obviously won't work.</p><p>At this point I attempted installation with the USB. I got a message that Windows was unable to create a new system partition or locate an existing partition. <a href="https://www.youtube.com/watch?v=o4ilMAAk1Q8" target="_blank">This video</a> was a great help, as I would not have figured this out on my own. The video runs through command prompts to format the drive, create a partition, and transfer the install. See the comments under the video as the drive needs to be converted to GPT. Otherwise you'll get another error during install. With all this done, installation of the OS finally began. This takes a while.<br /><br />
<span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span><br />It works! That was my biggest concern, after that was the heat sink and processor. Doing this again, the process would be a lot easier as I learned a lot along the way. I've always wanted to build a computer, so that was definitely a bonus. It works, looks great, and it was a fun project. I really like the case, and the price seems very reasonable. The glass panel is just cool. LEDs are a must, otherwise you can't see much inside.</p><p>How much did I save? I'm not sure. It's difficult to find a pre-built
that matches spec for spec. Looking just on Lenovo's site the closest
matches are over $1000. <br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4WwhtimASqpdONsR_RU0YVXg894C1sIk-JgoUaYyE4BsfWuEDKzeE2nP86roIYpm1EMD88duxVfDQsfvAB9pAOSZZMRPMMg_aoSdKJK9_G_xXgLO8o0wgkUcyQfQwWKmN1UOkkc1bHattU9C_3s6vK60EdHCT8Tqu8Q9xg1w0ldL1_oqS_R63dtsw/s640/IMG_0150%20copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4WwhtimASqpdONsR_RU0YVXg894C1sIk-JgoUaYyE4BsfWuEDKzeE2nP86roIYpm1EMD88duxVfDQsfvAB9pAOSZZMRPMMg_aoSdKJK9_G_xXgLO8o0wgkUcyQfQwWKmN1UOkkc1bHattU9C_3s6vK60EdHCT8Tqu8Q9xg1w0ldL1_oqS_R63dtsw/s16000/IMG_0150%20copy.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Completed build<br /></td></tr></tbody></table><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiciRidc4obOSN7fHcLBjlxonn_qGnlj6RsfyC-fiyEpjKkiCJcvC4MiBhDK28nBo1Gi8AoIMlQNYq2FViTbJOBLG18DtELAXdLm1SBjHEMTiIClqK2K4h_nUUmgEr7OT9kbCynLtj79NSRHqYuNxQj6pnTB9KNrm4sdIXcwCSjwA5-108Se6EwkRKc/s640/IMG_0149%20copy.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiciRidc4obOSN7fHcLBjlxonn_qGnlj6RsfyC-fiyEpjKkiCJcvC4MiBhDK28nBo1Gi8AoIMlQNYq2FViTbJOBLG18DtELAXdLm1SBjHEMTiIClqK2K4h_nUUmgEr7OT9kbCynLtj79NSRHqYuNxQj6pnTB9KNrm4sdIXcwCSjwA5-108Se6EwkRKc/s16000/IMG_0149%20copy.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Lights on<br /></td></tr></tbody></table>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-33182888699981172482022-04-29T02:00:00.256-04:002022-06-18T20:01:23.600-04:00Build a Closet Organizer<span face=""arial" , "helvetica" , sans-serif"><b>Closet Organizer</b></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcmaPkhfkuPnqs3zdfDNfYdWWBET9qmqGfwhSTu8w2gcWNagwxrJAQgECzsKx14l3GzseC6XPJY-Lk5Mdwaoow8OqXoClImOwOJSJ09N7RUVCLNo3mHN62-U9D5VurlxwcsLnHIwPvtnTA5ekqrZMDDMin_ca9LcNASR725WXotA8vBrc0w46enjLx/s640/cover.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcmaPkhfkuPnqs3zdfDNfYdWWBET9qmqGfwhSTu8w2gcWNagwxrJAQgECzsKx14l3GzseC6XPJY-Lk5Mdwaoow8OqXoClImOwOJSJ09N7RUVCLNo3mHN62-U9D5VurlxwcsLnHIwPvtnTA5ekqrZMDDMin_ca9LcNASR725WXotA8vBrc0w46enjLx/s16000/cover.jpg" /></a><br />
My contractor special closet was woefully inadequate and needed a big upgrade.
<br />
<a name='more'></a>My closet was a simple single bar and shelf. Once I decided to upgrade, I thought about how I used the closet, how I wanted to use it, and additional possibilities.<br />
<br />
<b>Purchase List:</b><br />
<div>
(2) <a href="https://www.homedepot.com/p/Columbia-Forest-Products-3-4-in-x-4-ft-x-4-ft-PureBond-Red-Oak-Plywood-Project-Panel-Free-Custom-Cut-Available-2588/204637005" target="_blank">4'x8' project grade plywood sheets</a> (prices have risen since I purchased)<br /></div>
<div>
(1) <a href="https://www.homedepot.com/p/Southland-1-1-4-in-x-10-ft-Galvanized-Steel-Pipe-566-1200HC/100533214" target="_blank">10' 1.25" galvanized pipe</a></div><div>(2) <a href="https://www.lowes.com/pd/SteelTek-1-1-4-in-Silver-Galvanized-Steel-Structural-Pipe-Fitting-Floor-Flange/999930954" target="_blank">1.25" galvanized pipe brackets</a></div><div>(8) <a href="https://www.homedepot.com/p/Rok-8-x-1-2-in-Philips-Truss-Head-Standard-Thread-Wood-Screw-Zinc-100-Pack-ROKS8X12TPSZ-100/303035163" target="_blank">1/2" Wood Screws </a><br /></div>
<div><a href="https://www.lowes.com/pd/KILZ-2-Interior-Exterior-Multi-Purpose-Water-Based-Wall-and-Ceiling-Primer-Actual-Net-Contents-128-oz/50252047" target="_blank">(1) Gallon KILZ paint or similar</a><br />(2) Quarts Semi-glass trim paint<br /><a href="https://www.lowes.com/pd/DAP-Alex-Fast-Dry-10-1-oz-White-Paintable-Latex-Caulk/3024883" target="_blank">Acrylic caulk</a><br /></div>
<div>
<b>Subtotal: $280 (I saved $140 by already having paint, caulk, screws and 1 sheet of plywood)<br /></b></div>
<div>
<br /></div>
<div>
<b>Tool List:</b></div>
<div>
table saw with crosscut sled<br />
circular saw</div><div>router with 3/8" rabbet (optional) and 1/4" straight<br /></div><div>hole saw 1.5"<br /></div><div>prybar and plate, hammer for demolition</div><div>screw driver<br />caulk gun<br />razor blade<br /></div>
<div>
<br /></div>
<div>
<b>Cut List:</b></div>
<div>
(2) 6'6"x13"vertical sides<br /></div>
<div></div>
<div>
(9) 9"x12.25" vertical shelves<br />(2) 6'1"x13" horizontal top/bottom<br />(4) 8"x12.25" horizontal dividers</div><div>(1) 6'-1"x3" bottom filler</div><div>(3) 3"x9" bottom support</div><div>(2) filler panels angled to match out of plane wall <br /></div><div>(4) 2"x10.5" drawer sides (route slots for drawer sliders)<br />(2) 2"x7.125" drawer backs<br />(2) 2"x8.75" drawer fronts</div><div>(2) 7.125"x9" drawer bottoms<br />(4) .5"x10.5" drawer slides (.25" MDF)</div><div>(4) .5"x10.l5" drawer slides (.125" plywood)<br /></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />
I started this project thinking about how I used the closet. From there I modeled the closet in Sketchup. This let me figure it out before I start cutting. I always try to maximize quality and cost. I settled on a double rod, lower shelf, and vertical shelf. I initially wanted to place the vertical shelf in the center of the closet, but the center of the closet and door aren't the same and the shelf would take up prime real estate. So I tucked it to one side. It could only go on one side otherwise it would be completely blocked. From there it was a matter of trying to maximize space and sizing.<br />I have 38" clear from rod to rod which is just about the minimum needed. The top most shelf only has 12" vertical clear, which is fine, but any shorter would make it unusable.<br />The lower shelf has 8" clear and is 12" deep, the vertical shelf is 9" wide and 12" deep.<br />Everything is 3/4" project grade plywood.<br />I bought 1.5" pipe forgetting that pipe is internal diameter, not outside. I should have bought 1.25" pipe as an overall 1.5" is the typical rod size. Since this is 1.5" pipe the overall diameter is 1.75". Clothes hangers fit on it fine, but it is just a bit large.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-Vu9oogrTxcxwp5tVSXyuz7hTJdu_w7uuctR5iqXKDgfcpLrIv91iqgvpaJbNN7NzPaH6cLQXOnTqnHY6hpOiMjYKSdAby-FioRJBBaRImmdR7zv_KBOjaQDED98Pi7xY4E8aCFER8dy7v4pjS6RHyrC9r4gtSlOvtzTNufRTRNP09T9Gh33IYEop/s640/IMG_9337.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-Vu9oogrTxcxwp5tVSXyuz7hTJdu_w7uuctR5iqXKDgfcpLrIv91iqgvpaJbNN7NzPaH6cLQXOnTqnHY6hpOiMjYKSdAby-FioRJBBaRImmdR7zv_KBOjaQDED98Pi7xY4E8aCFER8dy7v4pjS6RHyrC9r4gtSlOvtzTNufRTRNP09T9Gh33IYEop/s16000/IMG_9337.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Closet at the start before any demolition<br /></td></tr></tbody></table><p>I thought about starting this project at the beginning of 2021, but plywood prices had reached an all time high due to Covid. I revisited the project at the beginning of 2022 and discovered plywood was surging to a second high pricing peak. I proceeded anyway as I didn't want to put this off again.<br /><br /><span face=""arial" , "helvetica" , sans-serif"><b><span face=""arial" , "helvetica" , sans-serif"><b>Demolition</b></span><br />
</b>The first step was removing the clothes in the closet, then all of the trim. The shelf just sits on trim nailed to the wall. With that removed the rod is easy to remove as it sits in the trim on one side and slots into the other side. From there I removed the shelf trim and baseboard. I used a metal plate to distribute the force of the pry bar against the wall and help prevent denting the drywall. Pry the trim little by little along the length. Once it's out far enough from the wall pry at the nails, working along the length to remove trim.<br /></span></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Lower Shelf</b></span><br />
The lower shelf is divided into four sections that are 8" tall. I based the height on the shoes I want to store in it. <br />This shelf is roughly 6' wide, 12" deep, and 8" clear inside. For the top and bottom I used a rabbet to route ends and spliced two 3' long pieces for the top to avoid buying a second sheet of plywood. This is viable only because I planned to paint it. At one point I thought about doing solid wood, but the price would be too much.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLQrWSRef2uiINZmMonhVSL7ckcfRYBTLYPa0OKmTWTqcf7hp31p5rKESvpSGdTQjhFr9i_jlb9bVzmk1PKmpM_75AhSMcfC7kKJ9CXgDBk7MnjqQyjX7S6jn9UV2rmonHYw5Tkn3ukBP9ScSVk_BUwEv7I_xTAz15hJBAjYt-_4eThwQnLvZfnx2Y/s640/IMG_9344.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLQrWSRef2uiINZmMonhVSL7ckcfRYBTLYPa0OKmTWTqcf7hp31p5rKESvpSGdTQjhFr9i_jlb9bVzmk1PKmpM_75AhSMcfC7kKJ9CXgDBk7MnjqQyjX7S6jn9UV2rmonHYw5Tkn3ukBP9ScSVk_BUwEv7I_xTAz15hJBAjYt-_4eThwQnLvZfnx2Y/s16000/IMG_9344.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Bottom glued in first<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjswYPMYcEA6eTjHJGdnF43MmQAQP7-cm4NI_1mtkvhKDDdjS4fIIo9ix4jQVuQvV_1wIM6NtamQbLbGUnZsWn6siTpXKVn3Clh0xXEa63hJiV4CEaIN0lYt0qTdHjmYpO8aH0lUz0U0iXt10RjQYt1bs6OVC-VyKaD63wjfnAXzxKMW0EjrBKPpE8T/s850/IMG_9382.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="850" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjswYPMYcEA6eTjHJGdnF43MmQAQP7-cm4NI_1mtkvhKDDdjS4fIIo9ix4jQVuQvV_1wIM6NtamQbLbGUnZsWn6siTpXKVn3Clh0xXEa63hJiV4CEaIN0lYt0qTdHjmYpO8aH0lUz0U0iXt10RjQYt1bs6OVC-VyKaD63wjfnAXzxKMW0EjrBKPpE8T/s16000/IMG_9382.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Dividers and top shelf glued simultaneously<br /></td></tr></tbody></table><p>I had to construct this shelf in the closet as I wanted my tolerances as tight as possible to avoid filler panels and maximize space. If I built it outside of the closet, I'd have to reduce the width to account for rotating it into place.</p><p>I screwed in the lower shelf with one screw on each end into a stud.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Vertical Shelf</b></span><br />I built the vertical shelf separate. It's roughly 6' tall with four 6" clear shelves, and four 12" clear shelves. I wish I had made this 14" or 15" deep instead of 12" as my rod brackets are wider than expected. I had to pull the clothes rod in 1" which isn't bad, but is a bit tighter than preferred.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFpMg17pxwhi7lpmL4JrgdXfA5Sh09r8gN1sZggDxGi_N8FOzDvKe8nF1pwVaSs4v6AgH1f0movN6wH75sVmbSFUPqdoCopkQB19KU-xrBuRiXKSD7TxsaArD0sYwMJklGbgpYDw2dNPbeD7om1zzbEeYOTHWz0DqTwCMO7xXDxNoIk9SvHHAw7HSd/s640/IMG_9374.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFpMg17pxwhi7lpmL4JrgdXfA5Sh09r8gN1sZggDxGi_N8FOzDvKe8nF1pwVaSs4v6AgH1f0movN6wH75sVmbSFUPqdoCopkQB19KU-xrBuRiXKSD7TxsaArD0sYwMJklGbgpYDw2dNPbeD7om1zzbEeYOTHWz0DqTwCMO7xXDxNoIk9SvHHAw7HSd/s16000/IMG_9374.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Gluing up the unit in one swoop<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-z1I4c_BaIPdgfAg_i-drNOLHFzlN1Lu2qpsIMC4CcW09kL_IuFeRBHL0HmXiaHPT4exMbrPSeY9ZrOXu7v2mbv-MlLkrgzy2Is-nB2pAnjwfn7Yp5ia9Ps7byL8Fr3pTYlTeYTaMqQP7GDZnPmgUKciKB-4oOERHnkpvxzhWjNHBWXoKbrAehHb5/s640/IMG_9416.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-z1I4c_BaIPdgfAg_i-drNOLHFzlN1Lu2qpsIMC4CcW09kL_IuFeRBHL0HmXiaHPT4exMbrPSeY9ZrOXu7v2mbv-MlLkrgzy2Is-nB2pAnjwfn7Yp5ia9Ps7byL8Fr3pTYlTeYTaMqQP7GDZnPmgUKciKB-4oOERHnkpvxzhWjNHBWXoKbrAehHb5/s16000/IMG_9416.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Shimming prior to installation<br /></td></tr></tbody></table><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIX8f2XGvTQAKbY046BS78bJjQUvmsbHkKpHz3E1kc4LhsaZnbqNFcX3kBjh0FPm8apaXEoK2COIL9GTwm664vwINTcqmXof-DuPQWRdFPZ7o0iSkukbaH6lQO3e6Noh48upsl1qu3PSdVoxKC9F2HZrvIZx-cZAaJCh7K67FPwIsowZQnRjFEnpV0/s640/IMG_9415.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIX8f2XGvTQAKbY046BS78bJjQUvmsbHkKpHz3E1kc4LhsaZnbqNFcX3kBjh0FPm8apaXEoK2COIL9GTwm664vwINTcqmXof-DuPQWRdFPZ7o0iSkukbaH6lQO3e6Noh48upsl1qu3PSdVoxKC9F2HZrvIZx-cZAaJCh7K67FPwIsowZQnRjFEnpV0/s16000/IMG_9415.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNM_GmssYw_X3O6TCFWeMPT6eqWzHFtN0Zsu7sMEPBUHYU2o02pvpWEpLX0kePTObAxxj28xvlSTtR1v-0QsgIRxBSpsowrVQgLU5IX8LVcXw-Pvek5ye5zli1Cfp9n4qUFqpmYD170iEStEWlMbewPMlmoRkSZ6fbqmf8bnBHJmSOR6ZqVumQGL9Q/s640/IMG_9417.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNM_GmssYw_X3O6TCFWeMPT6eqWzHFtN0Zsu7sMEPBUHYU2o02pvpWEpLX0kePTObAxxj28xvlSTtR1v-0QsgIRxBSpsowrVQgLU5IX8LVcXw-Pvek5ye5zli1Cfp9n4qUFqpmYD170iEStEWlMbewPMlmoRkSZ6fbqmf8bnBHJmSOR6ZqVumQGL9Q/s16000/IMG_9417.jpg" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhf7836v28YJ764Lx4Gk2sFa_emLddV9IXAqt4PNhgrBT4VjUfjIud9-MoZIX4d_wHsAL-TYCarsFwon83ac7X9Swt7XLF6IHTtW7TC_f03O-Vk9QIRW_aSXFZxNHdhKXqb5Kp3Y8q1ObQdMTQDLHYft0UWoFaksy4U6YLcITmGLZzhZqPQq0tJQhh_/s640/IMG_9493.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhf7836v28YJ764Lx4Gk2sFa_emLddV9IXAqt4PNhgrBT4VjUfjIud9-MoZIX4d_wHsAL-TYCarsFwon83ac7X9Swt7XLF6IHTtW7TC_f03O-Vk9QIRW_aSXFZxNHdhKXqb5Kp3Y8q1ObQdMTQDLHYft0UWoFaksy4U6YLcITmGLZzhZqPQq0tJQhh_/s16000/IMG_9493.jpg" /></a>It didn't fit tight in the corner, even after rounding over the corner. The walls are square. I shimmed the vertical shelf so that it was parallel with the bottom shelf and then screw it into the wall. Since I was unable to hit studs, I used plastic anchors. I drilled holes through the shelf and into the wall, then removed the shelf and drilled larger holes for the plastic anchors. I attached it with four screws in each corner.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Drawers</b></span><br />I wanted a dedicated drawer for wallet, keys, etc. I made two 1.25" deep clear drawers with flush faces. I routed a 1/4" slot down each side.The runners are 1/4" MDF. I made a 1/4" MDF and 1/8" ply bracket for support. I wasn't confident the 1/4" MDF would be strong enough to glue to the wall without some support. I waxed the runners on the wall and the slots in the drawers. This makes them slide much better. I used .04 polystyrene plastic on top of one set of runners to reduce the gap of the drawer.<br /><br /><span face=""arial" , "helvetica" , sans-serif"><b>Double Rods</b></span><br />My closet is 6'2" wide, and I didn't want to have to buy (2) 10' poles just to cut them down. I bought one 10' pole and cut it in half. My shelf is 12" wide, but I wish I had made it 14" just to maximize space. The rod bracket is able to absorb 1.25" of space, but I did hole saw (2) 3/4" pieces of plywood and put them inside the bracket so the rod wouldn't move horizontally. On the opposite wall the trim has a 3/4" piece of plywood to fill space. That fills the 2" gap I have between rod length and closet width, but instead of filler, I could have made my vertical shelf wider and still had the same amount of rod length.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX6bOJoiY9XEcebmGQ2wy8a2RlR_WISBRycEjel7Mj4ppHs23QaxsfD29ADXDppGW6pBCuDBWPXu4SZaOp_AjLWty4g-qzxGok2REgsLRF4_LKOt98EJ6Ia7s6pqseIXFusuYLVKvZ05PwKbwydV-FFPDpHJBSfY5zOcEFdCXs2Dz6i4cd5tEI75zD/s640/IMG_9454.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX6bOJoiY9XEcebmGQ2wy8a2RlR_WISBRycEjel7Mj4ppHs23QaxsfD29ADXDppGW6pBCuDBWPXu4SZaOp_AjLWty4g-qzxGok2REgsLRF4_LKOt98EJ6Ia7s6pqseIXFusuYLVKvZ05PwKbwydV-FFPDpHJBSfY5zOcEFdCXs2Dz6i4cd5tEI75zD/s16000/IMG_9454.jpg" /></a><br />I used the baseboard from the bottom of the closet to create new trim pieces for the far end of both rods. A hole saw through the trim creates a resting spot.<br />I used galvanized brackets on the vertical shelf side. I created pilot holes and used screws that were 1/2" deep.<br /><br />
<span face=""arial" , "helvetica" , sans-serif"><b>Top Shelf</b></span><br />I reused the top shelf, moving the trim that supported it up the wall.<br /><br />
<span face=""arial" , "helvetica" , sans-serif"><b>Finish</b></span><br />I had to repaint the wall where trim was moved. I had KILZ white on hand, but it still took three coats to cover and blend. I used spackling compound for nail holes and for the end grain of the plywood and my splice joints. I accidentally dropped one of the closet rods and put a dent in the plywood. I might could have used a damp towel and an iron to bring out the dent, but I just spackled and sanded it.<br />The closet organizer was painted to match the trim in the room. I always use a semi-gloss on trim. For this application it makes it easier to clean as opposed to a satin or flat.<br />I cut some filler strips for the vertical shelf. As the gaps were 3/8" at the top/bottom and tapered to 1/8. A 1/8" gap can be caulked, wider than that would need a filler piece or backer rod. My walls just weren't in plane and I'm guessing it's because it was a closet and done quickly. The filler strips slope evenly and fills the gap so I just need caulk. For the bottom shelf I did use foam backer road on one side as the gap was a bit too big for just caulk.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhruQXZ97rTHa44oCqEakVQWhecilz9Bl5qHnEALyBmIe6dJgwC0hqMSizCENdu3ftsPd7Y7hxi6NpEP5ZD5OLkNdVXpM0ETLM00zexTTaQOQCZ1b_lvAS5AXRtk3sAxkLa6g2y4a5-g5uw3X6qN1cxcd9oOuBusYnsolEOWV2v51c5S6uW1x0gFndC/s640/IMG_9503.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhruQXZ97rTHa44oCqEakVQWhecilz9Bl5qHnEALyBmIe6dJgwC0hqMSizCENdu3ftsPd7Y7hxi6NpEP5ZD5OLkNdVXpM0ETLM00zexTTaQOQCZ1b_lvAS5AXRtk3sAxkLa6g2y4a5-g5uw3X6qN1cxcd9oOuBusYnsolEOWV2v51c5S6uW1x0gFndC/s16000/IMG_9503.jpg" /></a></p><p><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTC3-jxZc32ewJGxFtssvasnw5Py4F0HvjL0deJ_qnayEsJbEkRqbzqOpwgfZB-YzUI-3s2mv__sBK39MqTvT2L6wulKwmhPhpZf9rnIx2g00ZdkPXh7pG0PDg2_24-m23PGFov9j7J4YJ0EsDWH8QHT0RQY4Hg6RdxxUsBjKLJaJ05EndUh1P1V7b/s640/IMG_9508.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTC3-jxZc32ewJGxFtssvasnw5Py4F0HvjL0deJ_qnayEsJbEkRqbzqOpwgfZB-YzUI-3s2mv__sBK39MqTvT2L6wulKwmhPhpZf9rnIx2g00ZdkPXh7pG0PDg2_24-m23PGFov9j7J4YJ0EsDWH8QHT0RQY4Hg6RdxxUsBjKLJaJ05EndUh1P1V7b/s16000/IMG_9508.jpg" /></a> </b></span><br /><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguKT7PIOnOy8yjig0lcgclctJpq8mINzHWVf9TW62R4YElhtXun-UahA9hP23L0FI8yzv2rmeLz3bAs-nxQG-G7ethYaG8gLnI9A-4DmocCv0V-blNR5UdSIhZa1NjcFEj9uyiyvDrDTxnqtoCUA_CzVZLF2WmKBjqT-QjjDlRP_J5k91jeixJbEAu/s2016/IMG_9507.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1512" data-original-width="2016" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguKT7PIOnOy8yjig0lcgclctJpq8mINzHWVf9TW62R4YElhtXun-UahA9hP23L0FI8yzv2rmeLz3bAs-nxQG-G7ethYaG8gLnI9A-4DmocCv0V-blNR5UdSIhZa1NjcFEj9uyiyvDrDTxnqtoCUA_CzVZLF2WmKBjqT-QjjDlRP_J5k91jeixJbEAu/w640-h480/IMG_9507.jpg" width="640" /></a>Conclusion</b></span><br />This turned out exactly like I wanted. I wish I had made the vertical shelf an inch or two wider. At first I thought it should have been an inch deeper so the rods were centered from to back, but I actually like them an inch to the rear better.<br />My favorite part were the drawers for wallet, keys, etc. It's still my favorite part. <br />This closet fits so much more. While the top shelf is more difficult to reach, it's also a more efficient use of space.</p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-38411775267651060452022-01-07T02:00:00.192-05:002022-01-07T02:00:00.199-05:00Make a Spray Paint Can Mixer<span face=""arial" , "helvetica" , sans-serif"><b>Spray Can Mixer</b></span><br />
<a href="https://blogger.googleusercontent.com/img/a/AVvXsEhU0_iLgTTG3qrRSLepPKKoF2d5L1tWXFtL7m9WxINBmqkO4xYpTWm-PUnWsH09yGlzcXxuqYZPkqFvhjOSFfUMVx7snzARmHGqOL9MNFCY7DuU_l2tFr04-sAK8fXqrb9qaO_PQ127iQlVtl7e1jfA_KZMdc3kLoFmyhCoTgziPGPax24wdB0NRAH8=s640" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="366" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEhU0_iLgTTG3qrRSLepPKKoF2d5L1tWXFtL7m9WxINBmqkO4xYpTWm-PUnWsH09yGlzcXxuqYZPkqFvhjOSFfUMVx7snzARmHGqOL9MNFCY7DuU_l2tFr04-sAK8fXqrb9qaO_PQ127iQlVtl7e1jfA_KZMdc3kLoFmyhCoTgziPGPax24wdB0NRAH8=s16000" /></a><br />I've always wanted a better way to mix spray paint than shaking it by hand. <br />
<br />
<a name='more'></a>I've seen a mixer that is a jig saw attachment, but my jig saw quick disconnect isn't that quick. I recently saw a drill powered spinning mixer on <a href="https://www.youtube.com/watch?v=sSH1jS9FMcQ" target="_blank">Tested's Youtube channel</a>. Doubtful that spinning would properly mix, the video convinced me. With the product costing $50, I decided to make my own with scrap.<br />
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<b>Purchase List:</b><br />
<div></div>
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(7) <a href="https://amzn.to/3HrbmGy" target="_blank">3/16" pop rivets</a><br /></div>
<div>(1) 5.5"x13" <a href="https://amzn.to/3mJPs9q" target="_blank">sheet metal</a>, 18ga</div><div>(1) 4" diameter with (4) .5" tabs <a href="https://amzn.to/3mJPs9q" target="_blank">sheet metal</a> 18ga</div><div>(1) 3" long <a href="https://www.homedepot.com/p/Everbilt-1-2-in-13-x-6-in-Galvanized-Hex-Bolt-805736/204633223" target="_blank">full thread .5" bolt</a><br />(1) <a href="https://amzn.to/3eXKEsZ" target="_blank">1/2" nut</a><br /></div><div>(2) 1/2" <a href="https://amzn.to/3eEGSEv" target="_blank">fender washers</a></div><div>(1) <a href="https://amzn.to/3qEfjRo" target="_blank">EVA foam floor mat</a>, 12"x1"<br /></div>
<div>
<b>Subtotal: </b>I didn't buy anything, but if you had to buy everything it would be around $35<br /></div>
<div>
<br /></div>
<div>
<b>Tool List:</b></div>
<div>Drill with 3/16" bit, and 1/2" step bit<br /><a href="https://amzn.to/3mQz2vZ" target="_blank">Angle grinder</a> with 4" cut off wheel<br /><a href="https://amzn.to/3eGNUsA" target="_blank">Riveter</a><br />Vice<br /><a href="https://amzn.to/3pIamaX" target="_blank">Metal punch</a>/ hammer<br /></div><div><a href="https://amzn.to/3EKO8JH" target="_blank">Clamps</a> to hold metal while cutting<br /><a href="https://amzn.to/3zgss6V" target="_blank">Contact cement</a><br />Band saw<br /></div>
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</div><div></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I've always wanted a spray paint mixer. When I saw this one, I knew it would do what I wanted and I could make it out of scrap.<br />The mixer is composed of a tube, the base which fits inside the tube, and the bolt. The foam on the top inside edge of the tube helps the can stay in place with friction, providing enough compression.<a href="https://blogger.googleusercontent.com/img/a/AVvXsEhvT2kAOpoUqBz9LVKwkYRfKlb86Ux4sAT7C1wE-JSevz84bKTbQfpz2-6mseN2BlPYg0J__gucWvO0zSqiUsxk3ZkY98vWyhjijNJEV2K6ePgwDw4GgEm_DuQkIP-rrsmMSSa7sJaLrPYqp08BsUi0aKlC4Fc9bhMlxIHodW8j3IsKcVkYc71vG307=s640" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEhvT2kAOpoUqBz9LVKwkYRfKlb86Ux4sAT7C1wE-JSevz84bKTbQfpz2-6mseN2BlPYg0J__gucWvO0zSqiUsxk3ZkY98vWyhjijNJEV2K6ePgwDw4GgEm_DuQkIP-rrsmMSSa7sJaLrPYqp08BsUi0aKlC4Fc9bhMlxIHodW8j3IsKcVkYc71vG307=s16000" /></a>I made a cardboard prototype first to check sizing and operation.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Video Tutorial<br /></b></span></p><div class="separator" style="clear: both; text-align: center;"><span face=""arial" , "helvetica" , sans-serif"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/g6bn_71OLkw" width="500" youtube-src-id="g6bn_71OLkw"></iframe></span></div><p><span face=""arial" , "helvetica" , sans-serif"><b><br />Tube</b></span><br />The tube's height is 5.5" because that's the height of the scrap I had. It's 13" long which is as short as you can make it and still have room for the foam and can.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgtIqS44EJYKOmfTpQEbF_zquaMHRnwFsag3PT0nNoeSoVcmufes7wwLnrQznpYgNivIU_IXqdO4s60tSkG4UDPWQ9iY-MuCPRYa3pFgVOLpb5j9WilOyW967_-IZcv6xv6ka_5DAvq2owv0fb9FtnZ9pB0tUxWUZbqyHKKfapKnZfKOdFdD1-jIpFw=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEgtIqS44EJYKOmfTpQEbF_zquaMHRnwFsag3PT0nNoeSoVcmufes7wwLnrQznpYgNivIU_IXqdO4s60tSkG4UDPWQ9iY-MuCPRYa3pFgVOLpb5j9WilOyW967_-IZcv6xv6ka_5DAvq2owv0fb9FtnZ9pB0tUxWUZbqyHKKfapKnZfKOdFdD1-jIpFw=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The curve of the tube shaped with differently sized paint cans<br /></td></tr></tbody></table><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgxnWgAIjXMYcMCimUIXMxG7vIctI3ZzhRrq9wO-h8goDmhzUE2dvLgSuQBeHuMdfsfzZ9a0dM_AvwsYZfOneuUrrB5-Qrbr0UCuqx3u4I7jvRJv7WedfieUJH_wpDu_nNM8uANVysVkJMr6-JCgetmJNcTJpt0s07qtrNpWwjc3UfDSmTyuYN5jyoI=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEgxnWgAIjXMYcMCimUIXMxG7vIctI3ZzhRrq9wO-h8goDmhzUE2dvLgSuQBeHuMdfsfzZ9a0dM_AvwsYZfOneuUrrB5-Qrbr0UCuqx3u4I7jvRJv7WedfieUJH_wpDu_nNM8uANVysVkJMr6-JCgetmJNcTJpt0s07qtrNpWwjc3UfDSmTyuYN5jyoI=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Clamping the tube for attachment<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhKh6KYpuvC6H0fi2SeIdLsEDd6MwGQCqURw7SvGWuvvZ62WqQoN4jmLfbuvdM5LcMJOUYmPKwcl6mWcXCTl39L-bzIRN4nuiCT8ow2JJBamw7BqJ-VD0m_nIuwmlpbSLU-ExeTOub3mY8pZ6hxlGCO15LfQ7J6WqU5FRyo41yNP_ll6FwmEasKj5Af=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEhKh6KYpuvC6H0fi2SeIdLsEDd6MwGQCqURw7SvGWuvvZ62WqQoN4jmLfbuvdM5LcMJOUYmPKwcl6mWcXCTl39L-bzIRN4nuiCT8ow2JJBamw7BqJ-VD0m_nIuwmlpbSLU-ExeTOub3mY8pZ6hxlGCO15LfQ7J6WqU5FRyo41yNP_ll6FwmEasKj5Af=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Drilling holes for rivets<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjfJThpNgWthhgsoohiYqObFDb2uv37vLqplY1BscdG34WLAATQMmgRKZnz7BRcHK-1sz0oyntXzG60Yinh09HM-vcOEsWzL2vAi8bvdh7s25ZwBkTcnAEwFb02E6nK7E9G2jjpKTYS808N9wu1ufSZ1HdKudlROeknC4cnh-3aplyA34y9UZ4bLcXk=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjfJThpNgWthhgsoohiYqObFDb2uv37vLqplY1BscdG34WLAATQMmgRKZnz7BRcHK-1sz0oyntXzG60Yinh09HM-vcOEsWzL2vAi8bvdh7s25ZwBkTcnAEwFb02E6nK7E9G2jjpKTYS808N9wu1ufSZ1HdKudlROeknC4cnh-3aplyA34y9UZ4bLcXk=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Riveting the tube together<br /></td></tr></tbody></table><p></p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhCygm3VQLP9R5oWLFIr4q8iE5eP-Dc6j47H7a_4R0bCqsVmoeplb7J0r9nYaWrH_3FG0j8v6Zqn22OgxVH20LwFAwQ0gLQLYalVJt6Y9wJkwVMHE-L_6L9eSe4I1k2vBbcEHGaDIl5pPbeW7W0GAZeStcW5HrN0XQtjqlkr41Kd4XVkRN9MSKR_HHG=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEhCygm3VQLP9R5oWLFIr4q8iE5eP-Dc6j47H7a_4R0bCqsVmoeplb7J0r9nYaWrH_3FG0j8v6Zqn22OgxVH20LwFAwQ0gLQLYalVJt6Y9wJkwVMHE-L_6L9eSe4I1k2vBbcEHGaDIl5pPbeW7W0GAZeStcW5HrN0XQtjqlkr41Kd4XVkRN9MSKR_HHG=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Inside of the tube showing rivets<br /></td></tr></tbody></table><p>Once it was cut to size with the cut off wheel, I used a spray can and a larger can to curve the sheet metal. The spray can helps to start the curve, while the larger can helps maintain the desired radius. I clamped the ends with a .5" overlap. I drilled (3) 3/16" holes along the seam, then installed the 3/16" pop rivets with a riveter. I used a punch on the holes before drilling to prevent the drill from walking.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Base</b></span><br />The tube isn't perfectly round, which is okay. I traced the opening onto the sheet metal. I then sketched 4 tabs around the base, .5" square in shape. I clamped the metal to my work bench and cut the base out with a cut off wheel as close to my sketch as possible.<br />I used a vice to bend the tabs up, making sure the bend was inside my sketch line so the base would fit inside the tube.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEggFEn6qv-j4drO56XBJsa5XPqm1XPwtvIv3GoFtVy3ZBD_sUV07-wLAAlQMXPcI4KYGe5FQo7_QGU2UAvHiT9wxZK67g8jcYrdGvN0Pzslh8i40OMkgKU9GmiN0dYBigNFUhZwb54DzWk1UnXQQIFK4JYGXC5N7eR5YAgGJa-5RGUI8oEI66DlfNue=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEggFEn6qv-j4drO56XBJsa5XPqm1XPwtvIv3GoFtVy3ZBD_sUV07-wLAAlQMXPcI4KYGe5FQo7_QGU2UAvHiT9wxZK67g8jcYrdGvN0Pzslh8i40OMkgKU9GmiN0dYBigNFUhZwb54DzWk1UnXQQIFK4JYGXC5N7eR5YAgGJa-5RGUI8oEI66DlfNue=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Sheet metal base shaped with a cut off wheel<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgExO3N6HmmCnDiuQpvaE0pKUFjp0gWNHFQMOTnMAzmBA8bL5A79o83wIanT6eIMW1uCso0oFA2EX6wxfWsJ9wPb8UnvSav6-J64upc1HtyRw8l1DowILy7uGHfvgaL5WhN0egrvIhM4-phOF5uHCdRkSF_V7xh9A4B325nit_IRK-k1_9fvoXxC0kc=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEgExO3N6HmmCnDiuQpvaE0pKUFjp0gWNHFQMOTnMAzmBA8bL5A79o83wIanT6eIMW1uCso0oFA2EX6wxfWsJ9wPb8UnvSav6-J64upc1HtyRw8l1DowILy7uGHfvgaL5WhN0egrvIhM4-phOF5uHCdRkSF_V7xh9A4B325nit_IRK-k1_9fvoXxC0kc=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Bending the tabs of the base on a vise<br /></td></tr></tbody></table><p> The base is a tight fit in the tube which is good. I drilled through the tube and each tab and installed 3/16" pop rivets. I punched the holes first.<br /></p><p>I then drilled a 1/2" hole for the bolt. I made it slightly off center for centripetal motion. I feel like that will mix the paint better, but it's just a guess.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiDd_w43ZKI1UmYmz4mi9fo918buBT9HzeHfwDHsBD-hcb5HLrKpV8RD01zpJSNBONFycWVAcGKgeEAIitddgmoqvvgGdp8fqQFaV6_cDsEz3ZQIlqTkIIuDH2oi11vPX0uP7CBrHSV0FShjVPBcKpHMpNIgIzEYa5-ZFaHgTJdXwv5bHxBAIdh8ulC=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEiDd_w43ZKI1UmYmz4mi9fo918buBT9HzeHfwDHsBD-hcb5HLrKpV8RD01zpJSNBONFycWVAcGKgeEAIitddgmoqvvgGdp8fqQFaV6_cDsEz3ZQIlqTkIIuDH2oi11vPX0uP7CBrHSV0FShjVPBcKpHMpNIgIzEYa5-ZFaHgTJdXwv5bHxBAIdh8ulC=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Plywood sandwiches the foam to cut on a band saw<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiEW-vTZb7dZW8_-DKktjgAH5EGm9FPadg29jBvvODu_IgB5OjuqWoiWAJj6v9_bB0a1li2p0gWD4JN7_MjcfP-jWG2954VVk77tq1Y54JK6_2w6qfHC3o0U8Wox61J01mgbqT5YSQb4EApKzVGxJwYOnU9bBUUk_kd8bcn4ne-uapIM9ROnMIpvp3a=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEiEW-vTZb7dZW8_-DKktjgAH5EGm9FPadg29jBvvODu_IgB5OjuqWoiWAJj6v9_bB0a1li2p0gWD4JN7_MjcfP-jWG2954VVk77tq1Y54JK6_2w6qfHC3o0U8Wox61J01mgbqT5YSQb4EApKzVGxJwYOnU9bBUUk_kd8bcn4ne-uapIM9ROnMIpvp3a=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Bolt, washer, and nut.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgSC3q05DK2Vuu20-LR2TWf700qHvyFaKz4Pmn5hGa6ZPsKABoAa2IFAjZiXYCRD-oACZ15mVakgxQvIaH6wuUeCcwSQfUtc1vZb65__9us72LlChLJkL6r75n_EdW_MzpVuOh7c-tomyF9zY7jXfgNzzurHdg4Hq6MIfnkkI53rJbx8endZYoXsXVW=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEgSC3q05DK2Vuu20-LR2TWf700qHvyFaKz4Pmn5hGa6ZPsKABoAa2IFAjZiXYCRD-oACZ15mVakgxQvIaH6wuUeCcwSQfUtc1vZb65__9us72LlChLJkL6r75n_EdW_MzpVuOh7c-tomyF9zY7jXfgNzzurHdg4Hq6MIfnkkI53rJbx8endZYoXsXVW=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Foam glued to the interior perimeter<br /></td></tr></tbody></table><p>A fender washer on each side of the base with the through bolt and nut.<br /><br />
<span face=""arial" , "helvetica" , sans-serif"><b>Foam</b></span><br />I used the interlocking edge of a foam floor mat. It's cut to about 12" long. I had to cut it on a band saw vertically to make it thinner so it and the can fit in the tube. To cut it on the band saw, I sandwiched the foam between two pieces of plywood to keep my fingers safe.<br />I applied contact cement to the back of the foam and to the inside of the tube, let it dry for just a couple minutes so it was still wet and allowed for working time. I positioned the foam at the top of the tube.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span><br />
I filed all the metal edges so they wouldn't be sharp. I like the frame bolt as the end is a hex shape which fits in the drill well, but a regular bolt would provide enough grip.<br />This works exactly as intended, and it requires a lot less effort than shaking by hand. I'm sure thirty seconds of using this mixer is better than two minutes of hand shaking.</p><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='320' height='266' src='https://www.blogger.com/video.g?token=AD6v5dxXPXR4uRUrmGzss4nkfIymE6iilYahsQ4Kg4nL4KX0bLDLvE69lO1Grr-qwIriJM1G3cM90tOiltN0-ZQquw' class='b-hbp-video b-uploaded' frameborder='0'></iframe></div><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjJoXVzLgR2PNGEoHJidwBtCi1uXjheIXVMawM8LnNg1Iarar-b0iFp9cerWsofuEOEM2geHvMtwFVEI5TliKJSdGPw7AIKqKbxE52njYqNYBRsXQaU4VuoszGCT66nZZkMV64S3qb3Ucc4PoNBKY3C7ElWZ9Lv2kmRX0wfRJhljTToBdgX96XGtjFy=s640" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjJoXVzLgR2PNGEoHJidwBtCi1uXjheIXVMawM8LnNg1Iarar-b0iFp9cerWsofuEOEM2geHvMtwFVEI5TliKJSdGPw7AIKqKbxE52njYqNYBRsXQaU4VuoszGCT66nZZkMV64S3qb3Ucc4PoNBKY3C7ElWZ9Lv2kmRX0wfRJhljTToBdgX96XGtjFy=s16000" /></a><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgnNSMAKD5ZQ5P56-Y7T19qrABs06f3NtOx_xJ6pHkfZyVEpPmNrr0FFI0HD5nFqs918gYT7bW3ywEdHxbSqn9rB62c1oOHkIJSIrS5rfyN8LpTzq5wBTaCA-jRhp-8PLaQejX4sUSwaJmJELHupW0Z7lwgomvh5winsbw5Q3L30YRS7vONTuO9Ks8V=s640" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEgnNSMAKD5ZQ5P56-Y7T19qrABs06f3NtOx_xJ6pHkfZyVEpPmNrr0FFI0HD5nFqs918gYT7bW3ywEdHxbSqn9rB62c1oOHkIJSIrS5rfyN8LpTzq5wBTaCA-jRhp-8PLaQejX4sUSwaJmJELHupW0Z7lwgomvh5winsbw5Q3L30YRS7vONTuO9Ks8V=s16000" /></a><br />WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-1468940102974479282021-11-30T02:00:00.001-05:002022-01-02T20:02:49.647-05:00Replacing 95-99 Chevrolet OBS Exterior Door Handles with 88-94 Handles<span face=""arial" , "helvetica" , sans-serif"><b>Door Handle Mod</b></span><br />
<div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjU7hXO1tMTViAI2MjwZ7d9hZBuVbjKXdxmGOK5DtvPD4TFOp-fWYNFWTr2Ggt_9yXlgTfHGE1Bc65AMA3tIlGro8-l2QM4sKfEhmuZjh9yQV54B2AuPysAIaDYg6NAiehZvh3AkJJ0juIfdimuOqvR-6kuMohg-rsUGR0rFAjPt5Q4HTpa5lTmG9yv=s640"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjU7hXO1tMTViAI2MjwZ7d9hZBuVbjKXdxmGOK5DtvPD4TFOp-fWYNFWTr2Ggt_9yXlgTfHGE1Bc65AMA3tIlGro8-l2QM4sKfEhmuZjh9yQV54B2AuPysAIaDYg6NAiehZvh3AkJJ0juIfdimuOqvR-6kuMohg-rsUGR0rFAjPt5Q4HTpa5lTmG9yv=s16000" /></a></div><br />The 95-99 Chevy truck exterior door handles are prone to cracking. Replacing them with 88-94 handles that don't crack requires just a few mods.<br />
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<a name='more'></a>Both my exterior door handles were cracked. The 88-94 door handles are smooth with no texture and stronger. The 95-99 are textured and weaker, cracking around the lock. An easy way to determine the year of the truck is check the door handles. Textures ones will be cracked.<br />
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<b>Parts List:</b><br />Driver and Passenger exterior door handle from a 88-94 Chevrolet/GMC truck/SUV from a junkyard<br /><div>
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<b>Tool List:</b></div>
<div>flat head screwdriver</div><div>Phillips screwdriver</div><div>Plastic trim puller<br />T-25 torx head bit</div><div>10mm socket</div><div>belt sander or file for the lock cylinder if it doesn't fit<br /></div>
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<br /></div><span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />GM value engineered the door handles starting in 1995, using a cheaper metal that's prone to cracking. It's inevitable that the exterior door handles will crack and separate. I didn't want to replace the handles with a replacement that would just crack again over time. The 1988-94 handles don't crack.<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjT6fNbRGepoigPAhdeh6NcXuumaLQM1iIKooR-_z0aGaIQPxIMx1rDv4pKHOdV0DHO2-F5MMATgB7p24avBP6uNpOFsKui97ncuKM7uicbj6HT2qnNKhM5JAx5d5A4MwU0o7-WK4kXgKlR3ndppBTQA7EzRv8ljIFo14FTzSAZFjPRGE5bCSdHtBrj=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjT6fNbRGepoigPAhdeh6NcXuumaLQM1iIKooR-_z0aGaIQPxIMx1rDv4pKHOdV0DHO2-F5MMATgB7p24avBP6uNpOFsKui97ncuKM7uicbj6HT2qnNKhM5JAx5d5A4MwU0o7-WK4kXgKlR3ndppBTQA7EzRv8ljIFo14FTzSAZFjPRGE5bCSdHtBrj=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Smooth 88-94 handle on the left, textured 95-99 on the right<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjTVCpqgtmptHaRnPyhT9x3a5LDO5HmwSoz8h3_8EStlgbNwWyUad50RCEwTqKofRBjjGdWY3vdaeQf6ej-HNvkFs7Xh_ORFIcHgvrIygnDebEDyy-2rKlJkyouRPtBc_KzH3NgXsnJCGtW4tKGOlvvp-FrZfh3BzWgPGrwbS9dZACBDu_OU7wJbPZm=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjTVCpqgtmptHaRnPyhT9x3a5LDO5HmwSoz8h3_8EStlgbNwWyUad50RCEwTqKofRBjjGdWY3vdaeQf6ej-HNvkFs7Xh_ORFIcHgvrIygnDebEDyy-2rKlJkyouRPtBc_KzH3NgXsnJCGtW4tKGOlvvp-FrZfh3BzWgPGrwbS9dZACBDu_OU7wJbPZm=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The 95-99 handles always crack near the lock<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiJ94uNP0dKzy-bdDdnJFxZpokNfRSeiutQCJE8S0_EdNHiZCFS2_DL26E-WswJNAgV6tFlxmqv5fIv1dwIBj5p1niSPyrSuJxLyguXmuqPSGdNfq1DuVO4aB38bCl-NI1KFadg8ZxkWR2its0Y_hXLeDv2PbSA2acOGuWrpvwt_bNXwojvPDBgu7WC=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEiJ94uNP0dKzy-bdDdnJFxZpokNfRSeiutQCJE8S0_EdNHiZCFS2_DL26E-WswJNAgV6tFlxmqv5fIv1dwIBj5p1niSPyrSuJxLyguXmuqPSGdNfq1DuVO4aB38bCl-NI1KFadg8ZxkWR2its0Y_hXLeDv2PbSA2acOGuWrpvwt_bNXwojvPDBgu7WC=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">How 95-99 handles look when uninstalled<br /></td></tr></tbody></table><br /><a href="https://withwardworks.blogspot.com/2017/05/door-latch-removal-repair.html" target="_blank"></a><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Interior Door Panel Removal</b></span><br />Remove the door handle trim piece. There are three tabs total at the top, bottom, and side. A flat head screw driver can slightly depress the clips to remove the trim. </p><p>The triangular sail panel at the a-pillar just pulls out. Use your fingers or a plastic trim puller. <br /></p><p>Pry the back of the switch panel up, pull it backwards, then pull it out. You can leave the connections plugged in.</p><p>There are two phillips head screws in the armrest.</p><p>Plastic clips are around the entire perimeter of the door with a channel at the top that hangs the panel off the door.<br /><a href="https://withwardworks.blogspot.com/2017/05/door-latch-removal-repair.html" target="_blank">Here is the video tutorial on removing the interior door panel and door handle.</a></p><p><b>Exterior Door Handle Removal</b><br />There are (3) T-25 screws that attach the latch to the door. This provides enough leeway to reach the tab and rod on the back of the handle.</p><p>The handle is attached with (2) 10mm bolts. One is in the door jamb, one is through the inner door skin.</p><p>Pull the bottom of the exterior door handle out slightly, use a flat head screw driver to pry up the clip and release the rod. Turn the lock cylinder tab up, pull the bottom of the door handle out, and then pull the door handle down and out.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Lock Cylinder Swap</b></span><br />The locks have a clip that can be depressed with a flat head screwdriver. The slot is on top of the 95-99 handles, and on the bottom of the 88-94 handles. This allows the cylinder to be removed from the back.</p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEg5yWPYhBtIlcKu6TpSK8lmjG_jRSAF10RyKNLGXIThU7zttp5DFo0e9KYIYn8Iarp7E-YZ_wqijaN1mr71-viZMijPdsb1SHDH6sRCiuqP2ImQQp0mpkPYt_ETXT8FmV6vL4tXYAUCRrpeh05p1zZ3j5CcUgqGqsqfQ77vhtoORQMnscu8FI-0LsN9=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEg5yWPYhBtIlcKu6TpSK8lmjG_jRSAF10RyKNLGXIThU7zttp5DFo0e9KYIYn8Iarp7E-YZ_wqijaN1mr71-viZMijPdsb1SHDH6sRCiuqP2ImQQp0mpkPYt_ETXT8FmV6vL4tXYAUCRrpeh05p1zZ3j5CcUgqGqsqfQ77vhtoORQMnscu8FI-0LsN9=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The 88-94 handle has the receiver slot on the top, the 95-99 (pictured) has the slot on the bottom<br /></td></tr></tbody></table><p>The cylinder will need to be rotated to fit into the older style handle. Remove the pawl from the back of the cylinder with a flat head. You need to flip it and reinstall it 'backward' to maintain the same orientation. The pawl is keyed to the cylinder. Reinstall the retainer. You will have to flip the door latch rod clip.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjb5eNzI8-sZcdwJ2emDH3qxSV6XABJPGIY0D6wbf7DyXlcI7xB5dA4n8okt7tHoyluO6N8j40mDwnEQxrE75Q0K0qoFo3w8qE8hEFiZixGFZaQ05sbnkB0mk616MnwutR6UIWzEiEQuks-a30VNUscrMlg486hccGnvjNjErfojiLqxJAuJJDXWorE=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjb5eNzI8-sZcdwJ2emDH3qxSV6XABJPGIY0D6wbf7DyXlcI7xB5dA4n8okt7tHoyluO6N8j40mDwnEQxrE75Q0K0qoFo3w8qE8hEFiZixGFZaQ05sbnkB0mk616MnwutR6UIWzEiEQuks-a30VNUscrMlg486hccGnvjNjErfojiLqxJAuJJDXWorE=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The 88-94 door handle with the 88-94 cylinder<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjm1kHvhHJGuirPqiJkaX4dZ6o7PWrbowxcdzUyBlE1NPmk9Hz6D0JQezj31PpIEMXdxkZIvC18nalwnxGyfAs4YuUO0wj86DO5ykqK1nMtUwBF3uccsdycWUrN6e2NaTvKo6obSb0GGaVu1Dskjit1Crv-iNZblTNEMg6_vVHmyIEZ4WF2IVlgDKNK=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjm1kHvhHJGuirPqiJkaX4dZ6o7PWrbowxcdzUyBlE1NPmk9Hz6D0JQezj31PpIEMXdxkZIvC18nalwnxGyfAs4YuUO0wj86DO5ykqK1nMtUwBF3uccsdycWUrN6e2NaTvKo6obSb0GGaVu1Dskjit1Crv-iNZblTNEMg6_vVHmyIEZ4WF2IVlgDKNK=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The
95-99 cylinder on top rotated to fit. The pawl needs to be removed and
flipped so it's to the inside of the handle and not the outside.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEgpXuEJAOr9yBvYu8YSw6Hr3UjpfR_Ndft8a8igYkJ8umygXAIMnbk1mmWsNR_g-Gi0xOI01mC6p3jEo5eTD5nPy-1BxGhSIhX0D3LkvBmCoDAemHIo_s1CuRRnZ31GaTMx7g4CJdBbA-tyIkPbasKm585bLtACTSBciacn0YYEy4P6va1MlJq2yOkt=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEgpXuEJAOr9yBvYu8YSw6Hr3UjpfR_Ndft8a8igYkJ8umygXAIMnbk1mmWsNR_g-Gi0xOI01mC6p3jEo5eTD5nPy-1BxGhSIhX0D3LkvBmCoDAemHIo_s1CuRRnZ31GaTMx7g4CJdBbA-tyIkPbasKm585bLtACTSBciacn0YYEy4P6va1MlJq2yOkt=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The 95-99 cylinder in place in the 88-94 handle, before flippping the pawl<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEiBMJ5bARsgCpsEeqidABZAHoyuB6vIrikFamYrm5aE16n5eXr_lnKU4bvlimYTYxRDZlKuxtRGgzjWl7JsZKJ4OhaD2L3ORbmF2LPo27nmiAKOyDsIgAxYuX3BzgVgALpmNrM6ifO8MlrxLYB2MiiPZgmdY7jEryPM7vRLU8Ja2zEg308dv_zchEMi=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEiBMJ5bARsgCpsEeqidABZAHoyuB6vIrikFamYrm5aE16n5eXr_lnKU4bvlimYTYxRDZlKuxtRGgzjWl7JsZKJ4OhaD2L3ORbmF2LPo27nmiAKOyDsIgAxYuX3BzgVgALpmNrM6ifO8MlrxLYB2MiiPZgmdY7jEryPM7vRLU8Ja2zEg308dv_zchEMi=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The 95-99 cylinder in place in the 88-94 handle, after flipping the pawl<br /></td></tr></tbody></table><p></p><p>On one cylinder I filed down some ridges towards the front. While the cylinder was fully inserted, the clip didn't pop into the slot on the bottom back. The tension fit has so much friction I wasn't concerned with it popping out.</p><p>My passenger lock cylinder was too big to fit in the slot, just the passenger cylinder. I used a belt sander to file just a bit off of the entire cylinder so it would fit. It was able to fully insert into the cylinder and the tab popped into place.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjFtcZMVgN7enCcDpaHop08ZZiuWikX__EWt90dxX0n45Xh6jF3I67I_jHemrEbvSOZVdQ71n7FQKiqzQxXiYUd6-vNPG5wH7zVhxuAQCmv8xzrBjaK8XLdfJoCEthGJK1rHKNQnwswlZXXNcqZ_XHa4vE9b29yq_MefOkcC0Zj6Ru_15pYkg-tinC0=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjFtcZMVgN7enCcDpaHop08ZZiuWikX__EWt90dxX0n45Xh6jF3I67I_jHemrEbvSOZVdQ71n7FQKiqzQxXiYUd6-vNPG5wH7zVhxuAQCmv8xzrBjaK8XLdfJoCEthGJK1rHKNQnwswlZXXNcqZ_XHa4vE9b29yq_MefOkcC0Zj6Ru_15pYkg-tinC0=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The passenger cylinder has to be sanded to reduce the overall circumference to fit<br /></td></tr></tbody></table><p></p><p><b>Reinstall<br /></b>The older handles didn't have the rubber surround. I cut the rubber surround off my trucks handles and installed them on the replacement handles. While the 88-94 handle surround is thicker and don't have any lock points for the surround, this works fine. Once the handle is bolted in place it holds the rubber in place, Just be sure to have the rubber fitted right before tightening the bolts. Since there aren't any pins, be sure not to pinch or twist the rubber during reinstall.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEjU7hXO1tMTViAI2MjwZ7d9hZBuVbjKXdxmGOK5DtvPD4TFOp-fWYNFWTr2Ggt_9yXlgTfHGE1Bc65AMA3tIlGro8-l2QM4sKfEhmuZjh9yQV54B2AuPysAIaDYg6NAiehZvh3AkJJ0juIfdimuOqvR-6kuMohg-rsUGR0rFAjPt5Q4HTpa5lTmG9yv=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEjU7hXO1tMTViAI2MjwZ7d9hZBuVbjKXdxmGOK5DtvPD4TFOp-fWYNFWTr2Ggt_9yXlgTfHGE1Bc65AMA3tIlGro8-l2QM4sKfEhmuZjh9yQV54B2AuPysAIaDYg6NAiehZvh3AkJJ0juIfdimuOqvR-6kuMohg-rsUGR0rFAjPt5Q4HTpa5lTmG9yv=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">88-94 handle swap complete<br /></td></tr></tbody></table><p>When re-installing the handles, the short rod fits into the latch in a specific hole. When the handle is pulled up, this rod pushes the latch down to open the door.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Finish</b></span><br />These handles had some scrapes. I cleaned them well with acetone, primered them, sanded them with 400 grit, then applied spot putty to fill the scratches. I sanded the putty down, and primered the handles again.<br />After that I sanded the handles with 400 grit and painted them semi-gloss black.</p><p>While I could have tried to color match, my trucks paint is old and there's no way to get a good match so I kept them black. I have slick looking handles that won't crack now.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEilFrfb3UDWvUi_HzpXgKov6vMRbxAJqVKd1PUECuZDWxWpTgXBzYgKGTQZhLqSP98xGnw46DbayLp2zxfuQWoNXdhbuescpaNViFavTzmvXY_LSXX4yGWjJm0drNYxmSUk2M21fxezK4kLIW--HFAyndBeAbPLvEEsGRdjPr6A1uGIUQQb026lu7h5=s640" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEilFrfb3UDWvUi_HzpXgKov6vMRbxAJqVKd1PUECuZDWxWpTgXBzYgKGTQZhLqSP98xGnw46DbayLp2zxfuQWoNXdhbuescpaNViFavTzmvXY_LSXX4yGWjJm0drNYxmSUk2M21fxezK4kLIW--HFAyndBeAbPLvEEsGRdjPr6A1uGIUQQb026lu7h5=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The factory handle with a few scratches<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEioVHqeHCix8rdt7LxlsfZJ85ncvJbodSiIQlgEe0coxsYFcZI0NqIjAOKac72rTARZWPYZ2AMDF8h-29hV5O_FlyogHM6jCdyXTKl6mvo-Pz9-8wrtb1zRTFZNcKlWVNGHi75U5FSiX6iPhdq2Gplq4YXQsWUI3a2CsSqVgTj6vYFxy04Cx3qDCWmq=s640" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEioVHqeHCix8rdt7LxlsfZJ85ncvJbodSiIQlgEe0coxsYFcZI0NqIjAOKac72rTARZWPYZ2AMDF8h-29hV5O_FlyogHM6jCdyXTKl6mvo-Pz9-8wrtb1zRTFZNcKlWVNGHi75U5FSiX6iPhdq2Gplq4YXQsWUI3a2CsSqVgTj6vYFxy04Cx3qDCWmq=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">After first coat of primer and 400 grit sanding<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEh9tkZpN9wSRyS77xTw-3dAqqs9cix-krjut88mI4XHBmx5J8v0-2pm2q8vDoIwlLYOjs_gW1hr1BxWg-Uc4h829IH1U1SdENOkkgTlVUnJD10Dhwf0PqB43lf9gsXfKyElifc3XNd8P4lADeRUZrQLp_mdSnXESxqOerS5Hy-BafhFtnjvrTNOb32e=s640" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEh9tkZpN9wSRyS77xTw-3dAqqs9cix-krjut88mI4XHBmx5J8v0-2pm2q8vDoIwlLYOjs_gW1hr1BxWg-Uc4h829IH1U1SdENOkkgTlVUnJD10Dhwf0PqB43lf9gsXfKyElifc3XNd8P4lADeRUZrQLp_mdSnXESxqOerS5Hy-BafhFtnjvrTNOb32e=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Glazing putty<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEhlrjKRux3XL9OmhjONZjww1iUjpoG9OMVhKLrf6YcfqU1I7pTjrHxuP32jdRg3DzpZ4-rZ2PjpGNdxtvEt5cAMzh_LCw4u7h8fWSTey2hu1mhso4JMRFr9pjmmlFWPy0MXdRgQ8zfRIXR4hPKU1tPCDXnuAEmAau57G3sj1IcvGpUdj_rdcBZqnO_r=s640" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEhlrjKRux3XL9OmhjONZjww1iUjpoG9OMVhKLrf6YcfqU1I7pTjrHxuP32jdRg3DzpZ4-rZ2PjpGNdxtvEt5cAMzh_LCw4u7h8fWSTey2hu1mhso4JMRFr9pjmmlFWPy0MXdRgQ8zfRIXR4hPKU1tPCDXnuAEmAau57G3sj1IcvGpUdj_rdcBZqnO_r=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Glazing putty sanded and second coat of primer<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/a/AVvXsEi_wx6L1am1jMg6_-dwiE5jb0lzOxW5Hp-F4TIXfv_DxwpjxZbHpg-Ob9EQSM-b216mn3r1FR5NxnyGfiubLoL-9webE7JhmctEA3qZgTCeJMlCUgJGHu2UWx6LXvyxYJODcYWJdqDZz7TnHQ7JnpiY--51kEL8hz4dbS4epvQiu4eBp5MoSpbLv2Il=s640" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/a/AVvXsEi_wx6L1am1jMg6_-dwiE5jb0lzOxW5Hp-F4TIXfv_DxwpjxZbHpg-Ob9EQSM-b216mn3r1FR5NxnyGfiubLoL-9webE7JhmctEA3qZgTCeJMlCUgJGHu2UWx6LXvyxYJODcYWJdqDZz7TnHQ7JnpiY--51kEL8hz4dbS4epvQiu4eBp5MoSpbLv2Il=s16000" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Semi-glass black<br /></td></tr></tbody></table>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-16540513583694605812021-11-01T02:00:00.506-04:002023-02-03T09:24:37.867-05:00Scorpion Mortal Kombat 11 Costume Build<span face=""arial" , "helvetica" , sans-serif"><b>Scorpion MK11</b></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWUeLJz1uSazcsaMMAfyZBRdOAGQpFhYEV3czT0SGuxqfWqQr4WpedMnr6p6uIzWrUeUvOSJV5odxIkJAxkxHovNarqTbHjM0RJnPbRnqwuEN2DsHTdqZg57xVVytamidYst2xF0QZV8YqJ_M8WzXWIHRh6WYzLOMNpsIGfhQFURJiTmfhDIFpzbA6/s640/Scorpion.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWUeLJz1uSazcsaMMAfyZBRdOAGQpFhYEV3czT0SGuxqfWqQr4WpedMnr6p6uIzWrUeUvOSJV5odxIkJAxkxHovNarqTbHjM0RJnPbRnqwuEN2DsHTdqZg57xVVytamidYst2xF0QZV8YqJ_M8WzXWIHRh6WYzLOMNpsIGfhQFURJiTmfhDIFpzbA6/s16000/Scorpion.png" /></a><br />
Scorpion has been on my costume list for a while, finally I built it.<br />
<a name='more'></a><a href="https://crossthenetflixstream.blogspot.com/2020/06/the-mandalorian-season-1-review.html" target="_blank"><br /></a>I played the first couple of Mortal Kombat games, always as Scorpion, but I haven't played the latest iterations. I didn't even know there were so many games. My hesitancy with the costume was the simplicity and that I don't have the arms for it. I realized the latest version has a lot of detail apt for costuming and I could just add sleeves.<br />
<br />
<b>Purchase List (paid links):</b><br />
<ul style="text-align: left;"><li><a href="https://amzn.to/3ByVLkT" target="_blank">Ninja pants</a><br /></li><li><a href="https://amzn.to/3jS769w" target="_blank">Life size plastic skull</a><br /></li><li><a href="https://amzn.to/3w4gtaU" target="_blank">Mini plastic skull</a><br /></li><li><a href="https://amzn.to/3GDTAQQ" target="_blank">25' of black plastic chain </a>(didn't use)</li><li><a href="https://amzn.to/3bwsjRX" target="_blank">Wrestling shoes</a> (<a href="https://amzn.to/3nOjs3A" target="_blank">ninja shoes</a> would be more accurate)</li><li><a href="https://amzn.to/3mxcG2N" target="_blank">1" poly webbing</a><br /></li><li><a href="https://amzn.to/3EvYGN1" target="_blank">Aviator sunglasses</a></li><li>(6'-0") <a href="https://amzn.to/2Y353I9" target="_blank">2/0 Welded Zinc Plated Steel Chain</a><br /></li><li>(1) <a href="https://amzn.to/2ZJYLxT" target="_blank">Dye stripper</a> (project dependent)</li><li>(1) 1.5” o ring</li><li>(4) 1.5” <a href="https://amzn.to/3w51mOt" target="_blank">d rings</a><br /></li><li>(4) <a href="https://amzn.to/2ZEcQwV" target="_blank">buckles</a>/2 each arm (opted for p<a href="https://amzn.to/3jUy0NX" target="_blank">lastic tri-glides</a> instead)</li><li>6 yards of cord for shoulder rope/tassel</li><li>(1) <a href="https://amzn.to/3myH6la" target="_blank">black dye</a> </li><li>(1) <a href="https://amzn.to/3waWrvK" target="_blank">golden yellow dye</a> </li><li>(1) <a href="https://amzn.to/3pPgjmW" target="_blank">scarlet dye</a><br /></li><li>(1) <a href="https://amzn.to/3Evf0O0" target="_blank">dark brown dye</a> (project dependent)<br /></li><li><a href="https://amzn.to/37RUeep" target="_blank">EVA foam floor mats (4 pack)</a><br /></li><li><a href="https://amzn.to/37QKMb5" target="_blank">Craft foam</a> </li><li><a href="https://amzn.to/3kASdXz" target="_blank">Leather scraps</a></li><li><a href="https://amzn.to/3e6lTJP">Muslin perm press material</a><br /></li><li><a href="https://amzn.to/385ThiX" target="_blank">Styrene plastic .04</a></li><li><a href="https://amzn.to/3kX0Sne" target="_blank">3/16" Pop rivets</a></li><li><a href="https://amzn.to/3oTaemw" target="_blank">1/8" Pop rivet</a> <br /></li><li><a href="https://amzn.to/3CyfnXJ" target="_blank">Open ring snap buttons </a></li><li><a href="https://amzn.to/34PVUmP" target="_blank">1" hook & loop non-adhesive velcro</a></li><li><a href="https://amzn.to/3w0BQtQ" target="_blank">Speaker grille</a> <br /></li><li><a href="https://amzn.to/3oRB2Ub" target="_blank">Acrylic caulk</a></li><li><a href="https://amzn.to/2JxrugZ" target="_blank">Plasti-dip spray paint (2) cans</a></li><li><a href="https://amzn.to/3mLPZFs" target="_blank">Rustoleum spray paint</a> (1) can each (6 total): metallic
silver, flat black, flat brown, flat white, flat beige, gloss black<br /></li><li><a href="https://amzn.to/386lh5P" target="_blank">Acrylic paints</a>: black, brown, silver</li></ul>
<div>
<b>Total: $430 / I spent $205 as I already had a lot of this stuff. Buying everything will leave you with a lot of material for future projects<br /></b></div><div><b> </b><br /></div>
<div>
<b>Tool/Supply List (paid links):</b></div>
<ul style="text-align: left;"><li>pencil (I prefer a <a href="https://amzn.to/3jXMA4p" target="_blank">lead holder</a>)</li><li>marker</li><li>chalk<br /></li><li>scrap paper for sketching and for protecting work surfaces<br /></li><li>painters tape</li><li>duct tape </li><li>hobby knife with replacement blades</li><li>metal straight edge <br /></li><li>cutting mat</li><li>contact cement</li><li>3M 77 spray adhesive <br /></li><li>band saw</li><li>Dremel with cut off wheel<br /></li><li><a href="https://amzn.to/3oSnwzH" target="_blank">Wood skewers </a> <br /></li><li>drill with 1/8", 3/16" bit</li><li>sanding block/80 girt paper/220 grit paper</li><li>heat gun to seal foam<br /></li><li><a href="https://amzn.to/366f2wq" target="_blank">wood burning tool</a> to create battle damage in foam<br /></li><li>sewing machine, black thread, white thread</li><li><a href="https://amzn.to/3kSs8DC" target="_blank">seam ripper</a></li><li><a href="https://amzn.to/3eq3GXQ" target="_blank">rotary cutter</a></li><li><a href="https://amzn.to/383Dxgh" target="_blank">leather hole punch </a></li><li>contact cement</li><li>hot glue/hot glue gun</li><li>crazy glue </li><li>wood skewers for stirring contact cement, painting hard to reach crevices<br /></li><li>paint brushes</li><li>shop towels</li><li>respirator with organic vapor cartridges - contact cement is toxic, so is spray paint</li></ul>
<div>
</div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I started with <a href="https://www.google.com/search?q=scorpion+mortal+kombat+11&client=firefox-b-1-d&source=lnms&tbm=isch&sa=X&ved=2ahUKEwiyiLnRjp_zAhWbMlkFHaEPCVkQ_AUoAXoECAEQAw&biw=1440&bih=747&dpr=1" target="_blank">reference photos</a>. I googled Scorpion Mortal Kombat and started picking out looks I liked. I unknowingly decided on the MK11 version as that has a lot of details that lend itself to costuming.<br /></p><p>I think Halloween costumes should be creepy and I like to mask my identity. Because of that I decided to make Scorpion's face a skull which pays homage to one of his finishing moves in the original game. In addition to adding sleeves, I'm modifying the belt so it has a skull buckle that's part of an alternate in-game Scorpion. I like the look of it. I typically don't build weapons, while Scorpion does have two tantos on his belt, I'm not going to build those. Plus, I usually don't have the time anyway.<br /></p><p>My first step is listing all of the costume pieces. Next I begin detailing the items, noting colors, materials, and individual items. I sketch almost everything first to understand how it works, then I create a paper template to determine the correct size.</p><p>I had to dye a lot of leather and cloth. I ran into a few issues with that. For leather, be sure to prepare it by scrubbing aggressively with acetone. I did have one scrap of leather for which this did nothing and it didn't dye at all.</p><p>While I've dyed material with good results in a utility sink with just hot water in the past, that did not work this time around. I ended up dyeing on a stove which produced great results. In the utility sink the dye seemed to be half effective. On the cooktop I used just under boiling water with a bit of dish detergent per instructions. I don't know if was the heat, detergent or both that made a difference, but my blacks were gray/purple in the utility sink and vivid black on the cooktop. Same thing with red and yellow. It's baffling as I've dyed reds and burgundys in the utility sink before with fine results.</p><p><b>Video How To</b><br /></p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/_b2RXhnSqBE" width="320" youtube-src-id="_b2RXhnSqBE"></iframe></div><p><b>Mask/Hood</b><br />This is one of the trickier elements as skull masks are typically latex. Plastic ones don't cover the whole face. I found the largest life size skull I could knowing I'd have cut it up and enlarge it. I bought sunglasses to replace the eyes of the skull so I could still see while maintaining the illusion.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXykARV-VpOnxbWK76lXhAfjyNA41iDFTp0TUfL-tacNYnD6ryphKE2pj1faRGdjGwV9wSPbxd_pSFxClSi9su2wNMMo4YMiPL-P7BhyNZQLJyPUXUdBzN8SZhZC0Wthb022-QX8xzgVM/s640/IMG_7320.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXykARV-VpOnxbWK76lXhAfjyNA41iDFTp0TUfL-tacNYnD6ryphKE2pj1faRGdjGwV9wSPbxd_pSFxClSi9su2wNMMo4YMiPL-P7BhyNZQLJyPUXUdBzN8SZhZC0Wthb022-QX8xzgVM/s16000/IMG_7320.jpg" /></a></p><p>I cut out the back of the skull and below the cheekbones, cutting a bit at a time. I split the skull through each eye and dead center of the head. To widen it I used .040 styrene. Any time I heated the plastic I wore a respirator.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiB6qkxXyZXiuiRgUnnpLU6sYj9GtQGYsVn5ayzwBbry5_FPqUxAUOQKvVX_T9ynWsrWRLxdAgR7T1dZ3unBW-7icLrm2dRe_p-r_QtFmUPM9Ughub_YvlxZbae_mVDGELwTKRj8J2wk8/s640/IMG_7353.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiB6qkxXyZXiuiRgUnnpLU6sYj9GtQGYsVn5ayzwBbry5_FPqUxAUOQKvVX_T9ynWsrWRLxdAgR7T1dZ3unBW-7icLrm2dRe_p-r_QtFmUPM9Ughub_YvlxZbae_mVDGELwTKRj8J2wk8/s16000/IMG_7353.jpg" /></a></p><p>I needed to use CA/crazy glue. I didn't have any and tried Gorilla glue. That didn't work at all. CA glue did the trick. I used a strip of styrene cut to fill the gap and glued edge to edge. Then I used a strip of styrene perpendicular to the seam to bridge the gap and reinforce. I heated it first to shape it to the curves of the mask. Styrene heats quickly but also cools quickly. It gets very hot. I wore gloves to shape the pieces.</p><p>I used CA glue and clamped the plastic as it didn't dry as quickly as advertised. <br /></p><p>In the end I didn't need to split the entire skull. I could have just cut up through the eyes and then angled back to the center. <br /></p><p>To weld in the seams, I used a wood burning tool and scrap styrene, melting it to fill in the gaps. Wear a respirator with organic cartridge filters! I went slowly and tried to smooth out and feather as best I could. The filled seams are less noticeable than a gap. I used a hobby knife to cut out the eye sockets for a better fit against the sunglasses. It's not perfect, but it's good enough. I added pieces of foam on the inside for padding.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7FrIR_uUc7O7iB4-T1MmWQwtf5Hxo1Axc2moLQwgUmlmC2csRobYE3uh7xyyn81D1x632SopTiySsMf2IwYPgtFqesJSUs9MQlhyFUz_SngPRQwzZoJB7xVNjfAKIBdYPABS0Qgf3Fw/s640/IMG_7525.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7FrIR_uUc7O7iB4-T1MmWQwtf5Hxo1Axc2moLQwgUmlmC2csRobYE3uh7xyyn81D1x632SopTiySsMf2IwYPgtFqesJSUs9MQlhyFUz_SngPRQwzZoJB7xVNjfAKIBdYPABS0Qgf3Fw/s16000/IMG_7525.jpg" /></a></p><p>I painted it with a beige as bone is more of a warmer tan than cold gray. I then misted it with flat black to dull the gloss of the tan. I then used a glove finger to rub in the black and dull the color. I sprayed gloss black in the eye sockets to blend in the sunglasses lenses. I used a rag to feather the gloss into the beige. I kept it rough and loose. I want this to look messy. I went back with a black wash to add depth to the crevices. I used acrylic as I didn't want to affect the color of the skull.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4iYo9bHQ2i2L9yHyMzfbm1EFjENqkidw2E91lQ2ADOiIqcAxi_A5xebtZxKYWFCODA6XE_Ainjz5PjTzn32ybMFBiUcp8x43UaAUkFTjSlmMsJvBcXXZYlVHVX9ap4WFCwKQNDIZrvPw/s640/IMG_7522.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4iYo9bHQ2i2L9yHyMzfbm1EFjENqkidw2E91lQ2ADOiIqcAxi_A5xebtZxKYWFCODA6XE_Ainjz5PjTzn32ybMFBiUcp8x43UaAUkFTjSlmMsJvBcXXZYlVHVX9ap4WFCwKQNDIZrvPw/s16000/IMG_7522.jpg" /></a></p><p>I taped the sunglasses lenses in place and then hot glued around them to fill in gaps. The lenses really make the eyes look like a deep pit. Unless you look at it from the right angle, you don't see a seam.<br /></p><p>The hood is black exterior/red interior with pleats going down each side. Since my material was thin I did a double black layer. I started with a hood I sewed from a previous costume to get a sense of the right shape.<br /></p><p>I sewed the front edge/opening of the black and red together inside out, then I sewed just the black together inside out down the back. My pleats didn't meet in the back, so I had to redo it, lining up the pleats first. I also ended up sewing my pleats together from the backside as they kept expanding. If I had sewn my pleats in from the start I would have had cleaner lines, but the end result isn't bad.</p><p>I then turned the hood inside out to sewed the red interior together. The red liner is only sewn to the black at the front opening. I then sewed a line 1" back from the opening to keep the front edge in place, I wanted the black to curl into the opening just .25" and the only way to maintain that is to sew it in place. I did notice the reference hood has a 1" strip around the exterior opening. The pleats don't touch the opening, but I was too far into it to adjust.</p><p>The hood has a 'c' shape that drapes over the shoulders and down in the front and back. I sewed the hood to this and added open ring snaps in the front to secure it. <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5j-bSspbDSgPVB_Y81QDQ4DeJJKe_9xeCpZ4U_bAjQNs4fDkLIUU1KuePuSUA9DNlrHOTmaBw61s0cXVmA5804rnThIIcaQCVos4fP-552IrcemmOTWBX0LH2vTlQ6IxicgjN9zyyn8Q/s640/IMG_7920.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5j-bSspbDSgPVB_Y81QDQ4DeJJKe_9xeCpZ4U_bAjQNs4fDkLIUU1KuePuSUA9DNlrHOTmaBw61s0cXVmA5804rnThIIcaQCVos4fP-552IrcemmOTWBX0LH2vTlQ6IxicgjN9zyyn8Q/s16000/IMG_7920.jpg" /></a></p><p>The half mask is craft foam. I templated it first. I wasn't entirely happy with it, but time was running short. A curved cut helps creates a curve that wraps my face. I layered foam to create the look, with foam running down the middle and each side. I cut out the cheeks for the perforated metal. It's a speaker grille painted silver with black fabric behind it. I cut the speaker grille with a Dremel. I used hot glue to attach it to the mask.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq0iKcRhJcGhcm7pie82zCtRC7T4ai5Tm2ALS7_sXS_nnnDGDXXQpK0S3X7NiOmdHX1_G3yFWoeQ9U3WG30Z2Ieo5Jyv9dH6X04KrGNivQZPrCVVs97tJKf9hwwVGi699I6vyvIO_gQ28/s640/IMG_7523.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq0iKcRhJcGhcm7pie82zCtRC7T4ai5Tm2ALS7_sXS_nnnDGDXXQpK0S3X7NiOmdHX1_G3yFWoeQ9U3WG30Z2Ieo5Jyv9dH6X04KrGNivQZPrCVVs97tJKf9hwwVGi699I6vyvIO_gQ28/s16000/IMG_7523.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJwUAnBHTDm6fGeFaYUNlciR65PeETq7T1eyymtabRpz_l2jDXyiBOayO86SfkLO0E7FRCeCNGkOm1AXvI8HdUyn_SDi8HuGGM-Ykc1pnRWdYUO7mYpvavncLrcXJr78gMzuS3KfxKENY/s640/IMG_7530.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJwUAnBHTDm6fGeFaYUNlciR65PeETq7T1eyymtabRpz_l2jDXyiBOayO86SfkLO0E7FRCeCNGkOm1AXvI8HdUyn_SDi8HuGGM-Ykc1pnRWdYUO7mYpvavncLrcXJr78gMzuS3KfxKENY/s16000/IMG_7530.jpg" /></a>The half mask is attached to the skull with contact cement. I then glued an elastic band to the plastic skull, sizing it to my head.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5deVTDt5Aim5m0FhdOifSkNngvRsZjq1GGzDed0TFxuC9JfrtjckyYrEDr8XWonzx1yinOj4cHfO6RNqRye-57_-lIM7bDDyesFwOlEUM0aZImDxfs6SzPbN6hjVoRjKam-E9yT7j72U/s640/IMG_7916.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5deVTDt5Aim5m0FhdOifSkNngvRsZjq1GGzDed0TFxuC9JfrtjckyYrEDr8XWonzx1yinOj4cHfO6RNqRye-57_-lIM7bDDyesFwOlEUM0aZImDxfs6SzPbN6hjVoRjKam-E9yT7j72U/s16000/IMG_7916.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBVBIDP8PVkTuAnA8puI57O1bnlZS2DdVGcixV49_nVZboQMUcqCeQ_TYT68GvoTvvBpxu6E6lNgajuv1e8zG_cS3SBaPiVwf2GHtwQ_L6bdkh0dvIbaI7YRsOa0CXulOPkX_MriojODg/s640/IMG_7917.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBVBIDP8PVkTuAnA8puI57O1bnlZS2DdVGcixV49_nVZboQMUcqCeQ_TYT68GvoTvvBpxu6E6lNgajuv1e8zG_cS3SBaPiVwf2GHtwQ_L6bdkh0dvIbaI7YRsOa0CXulOPkX_MriojODg/s16000/IMG_7917.jpg" /></a></div><p></p><p><b>Tabard</b><br />The yellow tabard is classic Scorpion. Without it, it's just not Scorpion. I created a paper template to start getting the scale correct. It's an iterative process as I add and subtract until it looks 'right.' This can change as I template other parts. The costume is an ensemble. Adding new parts can make the scale look off for other parts.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxh520EcNnRPGfpRheuoNargtOJxUEBy3HjigpEzWZw_SsGWqQpNMcLwlM-ayVQTx4At8S6F-q4wqp3Z_yXAystoQQlC0R4FpiMCfm14NOnBG8jk3hzhTPYOBkx6cWgO6EwwOH-sJl8VI/s640/IMG_7073.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxh520EcNnRPGfpRheuoNargtOJxUEBy3HjigpEzWZw_SsGWqQpNMcLwlM-ayVQTx4At8S6F-q4wqp3Z_yXAystoQQlC0R4FpiMCfm14NOnBG8jk3hzhTPYOBkx6cWgO6EwwOH-sJl8VI/s16000/IMG_7073.jpg" /></a></p><p>I had leftover wool that I wanted to use as I liked the weave pattern and how it drapes. I tried dye stripping it, but I can only guess the gray wool is the natural color as the color remain unchanged.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyk9EQ7OHLZplZ4TSzaB3TvA5hpPnidfIXqVxfK0njksZnOuuUtlld9Jp8V2JPq0RzS8pYgZbNruZLXDXYNCdDMSyraFNCnoK_HjZd3c7M84QGQcG5a2pJuw5wLfwImniUqHrL7VcG7FU/s640/IMG_7463.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyk9EQ7OHLZplZ4TSzaB3TvA5hpPnidfIXqVxfK0njksZnOuuUtlld9Jp8V2JPq0RzS8pYgZbNruZLXDXYNCdDMSyraFNCnoK_HjZd3c7M84QGQcG5a2pJuw5wLfwImniUqHrL7VcG7FU/s16000/IMG_7463.jpg" /></a> <br /></p><p>I found material with an upholstery look which dyed well. I sewed it at each shoulder. I then cut and dyed leather for the perimeter.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTPfioba2tLPZErPooxWMW1MbDf_22l5Yw_mqJAx_nwtGhJV_I3HiDBkl-ZPa7wMDCHBYdXFgdTab3iQAYUxtsXdD9CAdQ0TJdA6fz76xk2uTnBbaxAYAPqe0312ZYQdZsJ3tSHxPT3lk/s640/IMG_7478.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTPfioba2tLPZErPooxWMW1MbDf_22l5Yw_mqJAx_nwtGhJV_I3HiDBkl-ZPa7wMDCHBYdXFgdTab3iQAYUxtsXdD9CAdQ0TJdA6fz76xk2uTnBbaxAYAPqe0312ZYQdZsJ3tSHxPT3lk/s16000/IMG_7478.jpg" /></a></p><p>I cut leather in 2" strips for the inside edging, folding it over and sewing it with black thread. I didn't have any strips the full length, so I cut them straight and sewed them end to end with a zig zag stitch. I had dyed the leather black, so cutting it exposed a tan edge. I used a sharpie for that. For the outside edge I had cut a 1/2" strip, but such a narrow strip was difficult to fold over and sew. I should have made it at least 3/4" wide. I ended up sewing it right at the edge instead of trying to fold it over. I didn't have time to cut and dye new strips.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4UDGYQxn3eDDU6HcCY9k-jWcDwGGR_Uk8Yd4Ua1H2Eam4eRmW0h6BFwsxO3J3L_jFj5gm8ZMUbFJb9cZ8tJ5TYsEDuY3ovZ5zLE452-8-hK5IMl1WrMyhyEvdXrbBrNzzGvdDwyDAn9E/s640/IMG_7485.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4UDGYQxn3eDDU6HcCY9k-jWcDwGGR_Uk8Yd4Ua1H2Eam4eRmW0h6BFwsxO3J3L_jFj5gm8ZMUbFJb9cZ8tJ5TYsEDuY3ovZ5zLE452-8-hK5IMl1WrMyhyEvdXrbBrNzzGvdDwyDAn9E/s16000/IMG_7485.jpg" /></a></p><p>The reference photos have additional strips of 1/2" black leather striping. along the inside and outside edges. I didn't have time to add it. The inside strip is spaced 1/2" from the edging. The outside edge has two 1/2" strips that but the edging. They have a basket weave type look that I planned to achieve by just sewing in a strip every 1".</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7xmUc7gJfMtM-0jvAw8skbaVfOMc8A4OVMf6P0WXEshVL6hguluRRSGRSZKrhrkMiXfC3IPQ0BPAVK1QPM37fxxunq7K9R22NBKFpZLjQsBAFTMeSWaA99QE5vJZreQJfju4frImXczY/s640/IMG_7532.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7xmUc7gJfMtM-0jvAw8skbaVfOMc8A4OVMf6P0WXEshVL6hguluRRSGRSZKrhrkMiXfC3IPQ0BPAVK1QPM37fxxunq7K9R22NBKFpZLjQsBAFTMeSWaA99QE5vJZreQJfju4frImXczY/s16000/IMG_7532.jpg" /></a></p><p></p><p><b>Shoulder Pauldrons</b><br />The pauldrons are foam floor mats. I created a relief cut on the inside to achieve the flare around the perimeter.</p><p>I started with a paper template, like everything else. From my original template I made them 1" wider and 3" longer. I sized it the way I wanted, cut them out, and then tried on the tabard template and realized the pauldrons were just a bit too big. They were 1" too wide, so I cut them back down and redid the relief cuts.<br /></p><p>I heated them to shape then to my shoulders, then glued a craft foam strip on the inside down the middle which will help hold the curve. I then cut a double 45 degree divot along the inside border to create the angle of the outside edge. I then glued a thin strip of foam into the divot to help keep the angle.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6Y2JajRCg7dbtiKVyDTBiINKtkiMAzaAfk-wlE8tkVw4u2ZahogkpB-MU8bnZu26lwZgGIACtugDcMP0l4yniSWCArXG1v86VfaQXoQG3EmQ2o6OPA62r0Wj7zlfgW5Il0LGu8d44FA0/s640/IMG_7196.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6Y2JajRCg7dbtiKVyDTBiINKtkiMAzaAfk-wlE8tkVw4u2ZahogkpB-MU8bnZu26lwZgGIACtugDcMP0l4yniSWCArXG1v86VfaQXoQG3EmQ2o6OPA62r0Wj7zlfgW5Il0LGu8d44FA0/s16000/IMG_7196.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTYrIYWCuxbJi70SKQ6DRl_fTYmmMl5gbKANDUuQZDXQVm5lyzAGRaJLWel99_0V-7o36Dqe3unwU3caZYf0df1mOsJoA8Ey6RDuKskg_7F7xLrzv9tMd0HQcMZEwUVpmxH6RRX-YcRZA/s640/IMG_7195.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTYrIYWCuxbJi70SKQ6DRl_fTYmmMl5gbKANDUuQZDXQVm5lyzAGRaJLWel99_0V-7o36Dqe3unwU3caZYf0df1mOsJoA8Ey6RDuKskg_7F7xLrzv9tMd0HQcMZEwUVpmxH6RRX-YcRZA/s16000/IMG_7195.jpg" /></a> Running front to back is a cord with tassels. I used 100% cotton rope, as that takes dye better than rope that contains polyester. Due to that I didn't have a choice in size.</p><p>The cord with loops and tassels took more time than expected. I had a
lot of false starts trying to figure out how to get from rope to a three
braid cord with two loops and two tassels. I'm very happy with the
result. I thought I might have to cheat it and make the parts
separately, gluing them together for the final piece, but what I ended
up with is basically one big piece. <br /></p><p>The rope is (3) strand typical twist braid. I unbraided the rope to create a typical (3) strand braid. I did a typical overhand knot with plenty of extra length. I then took each of the (3) strands and split them so I had (6) equally sized strands. From there I created (2) separate (3) strand braids. I then created two loops and tied them tight to mimic the two loops from the reference photos. I then adjusted the length of the (2) braids and did an overhand knot at the end of the braid. I then created a tassel. On half the tassels I had enough length to fold over to create the strands. On the other half I cut a length of rope, unbraided it, and made it long enough to fold in half to make the tassel. I used thread to tie a knot just above the knot that ends the braid. I folded down the strands and cut them if they had loops. Then I trimmed the end of the tassel to be even. I intended to dip it in black and then yellow dye for a few seconds but forgot. With time running short I sprayed it with gold paint which got the color close to the reference.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYneRsH6xLgXsOpVL1U7QWajx3-9Lq_DdECmgrjbCBCgEoloqh-1mdzVA4yHuEzCX26hCmi9cabWkdOfiwcqgVN73kselntyIdwMbixANgwgXS9nURWEam1SOx2sIjq2z5tacpaYTNQ6s/s640/IMG_7227.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYneRsH6xLgXsOpVL1U7QWajx3-9Lq_DdECmgrjbCBCgEoloqh-1mdzVA4yHuEzCX26hCmi9cabWkdOfiwcqgVN73kselntyIdwMbixANgwgXS9nURWEam1SOx2sIjq2z5tacpaYTNQ6s/s16000/IMG_7227.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZDk2upXxpetTa7Px58abHGzscukWBxZY6rxVTVXcCYlumvMyi90sX_ffc-BMZ6fxk7w7PYyz8YhTvKQaAwKGySaAj-VTlC3pyhAr8s6RxrqOM_9R02gIB-n8j50IGMVJvRiKCz-s6t2k/s640/IMG_7226.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZDk2upXxpetTa7Px58abHGzscukWBxZY6rxVTVXcCYlumvMyi90sX_ffc-BMZ6fxk7w7PYyz8YhTvKQaAwKGySaAj-VTlC3pyhAr8s6RxrqOM_9R02gIB-n8j50IGMVJvRiKCz-s6t2k/s16000/IMG_7226.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGsqTyYNXjwLCayO4AuvyNwyGeqORJZFDJqSk_b4pONoOOUm8Krf-Mhuc1CcEChjW0SLYOXrLkToe8VkFMt1XT00WLPmaC1xo7ULe9flKNzQK7ck-CIvzTuLtEt1157Qkz3s5Hehr4JXc/s640/IMG_7218.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGsqTyYNXjwLCayO4AuvyNwyGeqORJZFDJqSk_b4pONoOOUm8Krf-Mhuc1CcEChjW0SLYOXrLkToe8VkFMt1XT00WLPmaC1xo7ULe9flKNzQK7ck-CIvzTuLtEt1157Qkz3s5Hehr4JXc/s16000/IMG_7218.jpg" /></a></div><p>The pauldron has a brown leather center with (5) leather strips
across the pauldron with rivets. I cut brown leather and leather straps
for the pauldrons after silver paint. I used a leather hole punch in the
straps for the rivets. I used contact cement on the foam and spray glue
on the leather to adhere them. The straps running across the pauldron
secures the cord and loops. I put one rivet in the leather straps on
each side instead of two as I didn't want to buy more rivets. It would
take 40 total per the reference!</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC0JBcAHXirIH3sjUG34w75TlrSyX9C1S3X2t7_GHQeYg1WdnMFfq6d3I81fU5eSXWxHy0Edx1g-JydsNWCqwO12a244z9jRFNRqT0ifAlwHvmjaRq5vm2Li7u1nL6n4SwvEzGtcg7_gw/s640/IMG_7531.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC0JBcAHXirIH3sjUG34w75TlrSyX9C1S3X2t7_GHQeYg1WdnMFfq6d3I81fU5eSXWxHy0Edx1g-JydsNWCqwO12a244z9jRFNRqT0ifAlwHvmjaRq5vm2Li7u1nL6n4SwvEzGtcg7_gw/s16000/IMG_7531.jpg" /></a> A strip of 1" leather connects
the pauldrons in the back. The 1" strip in the front has a 1.5" metal
ring centered. I have velcro on one end that attaches to the back of the
pauldron to make removal easier.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqd7Obd9NK8F8jRD7AtPrDJ_LUTMGt3OggpMwem3f-ZCA4TM__jDc50qmknNDsyOGqM889RPau67Db9Ws4gCejCdawa8rYYAEEMddIUY_BEww895p2TLq6WpgCxtKIELf_bjBWxYtCfY4/s640/IMG_7851.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqd7Obd9NK8F8jRD7AtPrDJ_LUTMGt3OggpMwem3f-ZCA4TM__jDc50qmknNDsyOGqM889RPau67Db9Ws4gCejCdawa8rYYAEEMddIUY_BEww895p2TLq6WpgCxtKIELf_bjBWxYtCfY4/s16000/IMG_7851.jpg" /></a> <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsTrLfzH0kSyhwA1Fq-3FtH1eg5AfSU_gK3nLedZ0KwU-p2Yst-eUjEbpBZWQkZOacKWstfQMrMdwm-OElOwhhX_MpsJIUC2sSa-PmuyaJ9J27QUfjhhjIL5MsMd5ffALUgm47Bc01LXc/s640/IMG_7923.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsTrLfzH0kSyhwA1Fq-3FtH1eg5AfSU_gK3nLedZ0KwU-p2Yst-eUjEbpBZWQkZOacKWstfQMrMdwm-OElOwhhX_MpsJIUC2sSa-PmuyaJ9J27QUfjhhjIL5MsMd5ffALUgm47Bc01LXc/s16000/IMG_7923.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK-08VTyPvw2x6kUmEE8alexJuNlng2I8v7_UuiEU-m3w4Poom6H5PGxFLutQY1agJD7tsLp-WgWG3l8TGIxfm6YW-V8WGZ8mRTJ9yFyKqdI5gltXCDCCpnke5QYHdiLs97QVgjFl9e7Q/s640/IMG_7924.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK-08VTyPvw2x6kUmEE8alexJuNlng2I8v7_UuiEU-m3w4Poom6H5PGxFLutQY1agJD7tsLp-WgWG3l8TGIxfm6YW-V8WGZ8mRTJ9yFyKqdI5gltXCDCCpnke5QYHdiLs97QVgjFl9e7Q/s16000/IMG_7924.jpg" /></a></div><p><b><b>Undershirt/Gi</b><br />
</b>I used a button down long sleeve shirt as a starting point. I try
not to start from scratch when possible. It seemed about the right size,
so I created a template off of that. Using a reference makes creating
templates much easier and if you're new to sewing you can also use it as
a reference for stitching.</p><p>While Scorpion's gi doesn't have
sleeves, I need sleeves. They will be black, and I added a diamond
stitch pattern for texture. The neck is red, and I'm going to add a red
stripe under each arm.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxH1xGazVu1bz637D6UoYErn09wVNF0dOlYxV247ouEUCrIJhQUbURV5_ID1oUOk6bBMMdLUFDBMv5NJwJ3z8j1mw9IhnB6dzaDCvRdgF2N_kZnouudAv_KuaRrpA7_xOMwbENUxu3ClE/s640/IMG_7421.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxH1xGazVu1bz637D6UoYErn09wVNF0dOlYxV247ouEUCrIJhQUbURV5_ID1oUOk6bBMMdLUFDBMv5NJwJ3z8j1mw9IhnB6dzaDCvRdgF2N_kZnouudAv_KuaRrpA7_xOMwbENUxu3ClE/s16000/IMG_7421.jpg" /></a> <br /></p><p>There were ten different pieces to the gi. I
was surprised I didn't mess up more than I did. I accidentally twisted
the piece from front to back when sewing. Thankfully with fabric, it's
easy enough to rip the seam and redo it. I referenced the shirt I took
measurements from to determine how to line up my pieces. I tried to line
up edges, either one end of the other. I sewed everything inside out to
hide the seams. asdf<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiieVePJs-QY-YW5c-1qXTURSByubJ_z6pxm9afIQP6Z_XDOqA_h25cMaTSzVBi8S_mSi6c6sSBo04mxuPvVRqyC_pIvxhn_8An5QZzT0hAwWCVd431VsICIDtN2YBcn-4d9sd6OfGvJVU/s640/IMG_7499.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiieVePJs-QY-YW5c-1qXTURSByubJ_z6pxm9afIQP6Z_XDOqA_h25cMaTSzVBi8S_mSi6c6sSBo04mxuPvVRqyC_pIvxhn_8An5QZzT0hAwWCVd431VsICIDtN2YBcn-4d9sd6OfGvJVU/s16000/IMG_7499.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhBy9y6J4Z57UqacfUw2TPPeiNbBXVXdCnSyES0xBHhHg7Hx7_bC4Y2TO6mL3S8uZPl81yiMDf5HBRQHW9ZfsK6JTD-8mzMWZdPEvN66M_FCorShQ_jERGv8j3Y_M4Re3KXY6qfENSElA/s640/IMG_7500.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhBy9y6J4Z57UqacfUw2TPPeiNbBXVXdCnSyES0xBHhHg7Hx7_bC4Y2TO6mL3S8uZPl81yiMDf5HBRQHW9ZfsK6JTD-8mzMWZdPEvN66M_FCorShQ_jERGv8j3Y_M4Re3KXY6qfENSElA/s16000/IMG_7500.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8v6epkKb0ecSe3Z_49icauLzlilofsiepdaFyzb4a55Q3L2cH-5-rav2IGZ8_8a_AK2wSLPmu0JPhd22Ljsv16-hhvtNvyk72PhWzLasdDk59S3ye2QX1clvX4p63-w0rwwoKcO8g56s/s640/IMG_7501.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8v6epkKb0ecSe3Z_49icauLzlilofsiepdaFyzb4a55Q3L2cH-5-rav2IGZ8_8a_AK2wSLPmu0JPhd22Ljsv16-hhvtNvyk72PhWzLasdDk59S3ye2QX1clvX4p63-w0rwwoKcO8g56s/s16000/IMG_7501.jpg" /></a></div><p>Before sewing the sleeves together or to the gi,
I added a diamond pattern to both sleeves for texture. It's easier to
do it before sewing it up. I had to recut the neck to fit better. I
hemmed all edges for a finished look. It turned out really nice. The
black/red looks really sharp. It's a shame you don't see much of the
undershirt. Since it is a gi, and if you look at the reference photos,
the collar should have edging which mine doesn't.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNn9GNrjhoajwOtm8qLHNEy5s8XxnsLQ6L_74QaZtMPUCTp65nU85yA5rG4CFBcHjFafzkk8oPcgiReg5zvyyUm_2m21hzvh8Lr8HCpVA0OqAEzvCxED4EB4Np-INVapjnCmAIz-yg-DU/s640/IMG_7912.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNn9GNrjhoajwOtm8qLHNEy5s8XxnsLQ6L_74QaZtMPUCTp65nU85yA5rG4CFBcHjFafzkk8oPcgiReg5zvyyUm_2m21hzvh8Lr8HCpVA0OqAEzvCxED4EB4Np-INVapjnCmAIz-yg-DU/s16000/IMG_7912.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLc0pVXRwwa4LS2GZ1srHvWDgW4Pm5K_VEkSNrU_5ITnX9cGDoAJy7FfHgNcx-u9wIa3hYnPADdpYEaPp-egURQtikqnVjAN7AAQ43rjXjJhr-xiJSMraQTen61dIna2gLgEwROZwfHuc/s640/IMG_7913.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLc0pVXRwwa4LS2GZ1srHvWDgW4Pm5K_VEkSNrU_5ITnX9cGDoAJy7FfHgNcx-u9wIa3hYnPADdpYEaPp-egURQtikqnVjAN7AAQ43rjXjJhr-xiJSMraQTen61dIna2gLgEwROZwfHuc/s16000/IMG_7913.jpg" /></a></div><p><b><b>Belt</b><br /></b>The belt is 5" tall EVA foam. I added (2)
strips of poly web on the inside for strength with contact cement. Foam can easily tear.
Tri-glides on the front act as the buckle. </p><p>The
front buckle is foam, with a plastic skull, and craft foam trim
attached with contact cement to a leather and poly web sleeve that will
conceal the tri-glide buckles. I made the craft foam trim one big piece,
but should
have made it individual pieces to make glue up easier. The belt buckle
is foam floor matte with craft foam trim. The skull is a
small plastic one that was cut to fit the belt. I painted the buckle
with plasti-dip, then painted the trim and skull gold after masking.
After the test run, I cut the polyweb straps of the buckle and added
velcro to make it easier to add and remove.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVFIbsLf7rbK1T_nWChM0fQv-bxBqE43Ezh9eTOsLlBODFUgSWESsbVRAjv_KE-6MWe7hIQ02ym5zxdCg9rOj8tR9ONv0I2KnsbUVRLPGtgNP7mW3RNwiSbOqGiOuURUXA2zEZrMSs8lM/s640/IMG_7194.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVFIbsLf7rbK1T_nWChM0fQv-bxBqE43Ezh9eTOsLlBODFUgSWESsbVRAjv_KE-6MWe7hIQ02ym5zxdCg9rOj8tR9ONv0I2KnsbUVRLPGtgNP7mW3RNwiSbOqGiOuURUXA2zEZrMSs8lM/s16000/IMG_7194.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYNE_IWWir9e8W_Xa-hg4P8js3jr8JMAvGfuckw3Psr6o-_QzRaeWFzYo60sHZZMSt5CMa9h3-GzWlhhuOHFiD49wLvt4FGb_pLqHpEhwYmoY4leimEk9rsTIqJDgiw7x4b15Ucj4lD7Y/s640/IMG_7515.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYNE_IWWir9e8W_Xa-hg4P8js3jr8JMAvGfuckw3Psr6o-_QzRaeWFzYo60sHZZMSt5CMa9h3-GzWlhhuOHFiD49wLvt4FGb_pLqHpEhwYmoY4leimEk9rsTIqJDgiw7x4b15Ucj4lD7Y/s16000/IMG_7515.jpg" /></a>I added craft foam perpendicular to the poly web at each edge to reinforce it as the polyweb was wanting to separate.<br /></p><p>The
brown leather I originally planned to use for the belt didn't accept
dye at all. I ended up dyeing other pieces. I wrapped the belt in
leather
that I dyed black, with contact cement. On each side is a leather
sleeve with each edge hemmed. They are glued in place and don't move. I
used spray glue on the backside of the leather before applying contact
cement as this stops the leather from absorbing the contact cement.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6baYYrrmFW_GryS5BRWzxxhgl-Ml1hlP3NeFHVle6mIMmJgSi3BNrF6R5WUmRzwBgWItq42STlAegAWEW5_mDraT5WRubvJ2P4NVw2h9ihN0YWNH2a1HqDeTw-g9ugaNQHDx2A-jyz5E/s640/IMG_7352.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6baYYrrmFW_GryS5BRWzxxhgl-Ml1hlP3NeFHVle6mIMmJgSi3BNrF6R5WUmRzwBgWItq42STlAegAWEW5_mDraT5WRubvJ2P4NVw2h9ihN0YWNH2a1HqDeTw-g9ugaNQHDx2A-jyz5E/s16000/IMG_7352.jpg" /></a></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_PBtUjB_Z2btwIUpHEBHgMYpjFrsAxM9FHO-SF_PRWGErpO4o56LBKUPvO9q3M-odajBZzVjfW7SeMOGzqSYcSPOCCG2NqgWkXwMzNXnPiMFDUXGoExGhkxUbiMzUikv62tn6KeCCDj8/s640/IMG_7425.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_PBtUjB_Z2btwIUpHEBHgMYpjFrsAxM9FHO-SF_PRWGErpO4o56LBKUPvO9q3M-odajBZzVjfW7SeMOGzqSYcSPOCCG2NqgWkXwMzNXnPiMFDUXGoExGhkxUbiMzUikv62tn6KeCCDj8/s16000/IMG_7425.jpg" /></a></div><p>I
had planned to have plastic chain run inside the sleeves, but I was
short on leather so my original idea would have allowed the foam to
show. The plastic chain looping around the belt would have been a cool
look and fits the character. I thought about instead looping it around
the belt, but didn't have time to paint the plastic chain. I opted out
of metal to reduce weight.<br /><br />There are three red/black towels hanging from the
belt. The plan was to dye the blue/gray leather I had, but after the
tabard not dye stripping I had concerns.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTQWDFyKbZJ8VvER7XGHIDDLF2Opi95WggaeYC3oXT2cLhwx7nLdGb6Pzewb28Mt0niJ_7Dgo0mQGBZNmfHXeisAIePatNjB67N1OBjnbaioGwUOtrvOfFmujBthmPyQdktEqs87d8nPg/s640/IMG_7275.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTQWDFyKbZJ8VvER7XGHIDDLF2Opi95WggaeYC3oXT2cLhwx7nLdGb6Pzewb28Mt0niJ_7Dgo0mQGBZNmfHXeisAIePatNjB67N1OBjnbaioGwUOtrvOfFmujBthmPyQdktEqs87d8nPg/s16000/IMG_7275.jpg" /></a></div><p>What absolutely helped
was rubbing the smooth side of the leather down with acetone. The better
you scrub it the better it will accept the dye.</p><p>After ten
minutes, the smooth side of the leather had turned a purple color. The
rough side was full black. I wrote this off as a failure, but did leave
it in the dye bath for a full hour as recommended. The end result is
that one towel was mostly black. One was kind of purple,
and the other look half dyed. I either didn't acetone scrub it or did a
poor job. This did give me hope for dyeing the belt black.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnN08RIcRrl7KO32p2-CfHd5SdeQxWucRHj_ZjEuzDF09AXen9L6eo8rX32iHZSm2kckB4q3r_6mw8hjF6Ouo6xpr3HXjAt4lq0px47AiweBDa_VBLnG0stTDraUazniJCNxtjpf2Mw-4/s640/IMG_7261.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnN08RIcRrl7KO32p2-CfHd5SdeQxWucRHj_ZjEuzDF09AXen9L6eo8rX32iHZSm2kckB4q3r_6mw8hjF6Ouo6xpr3HXjAt4lq0px47AiweBDa_VBLnG0stTDraUazniJCNxtjpf2Mw-4/s16000/IMG_7261.jpg" /></a></p><p>I tried
again with the red portions of the towels. This time I fully saturated
the leather while scrubbing it with acetone. The results were much
better, the dye was even and more vivid.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZktyRvaYPysAKZF-fBdjdvR2xvIgoevNQsWAVF0poq6qSjERs_XWBhuAvTrCPxSxeh8kBKbA-kS4s4ghyphenhyphenjZYyNhg1tNN3hOl1X69YTqsi_uE_123s-vYX-TQYq67rBNtvqRuRt4TnzNE/s640/IMG_7273.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZktyRvaYPysAKZF-fBdjdvR2xvIgoevNQsWAVF0poq6qSjERs_XWBhuAvTrCPxSxeh8kBKbA-kS4s4ghyphenhyphenjZYyNhg1tNN3hOl1X69YTqsi_uE_123s-vYX-TQYq67rBNtvqRuRt4TnzNE/s16000/IMG_7273.jpg" /></a></p><p>I ended up redying the
black on the cooktop. It came out much better. I assume because of
dyeing on the cooktop, the black leather shrank. I stretched it so that
it matched the red, using duct tape on the back. With the need to
stretch it to fit, I opted out of contact cement as I didn't think I
could get it right on the first time. While all edges line up, the
towels do wrinkle as the black wants to return to size. It doesn't look
bad. I really like the red/black look. The towels are attached to the
belt with contact cement. For some reason the towel in the front is
above the tabard and in the back behind it. I didn't glue the last 2" of
the towels to the belt in the back so I could just tuck the tabard in
front of it.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCp3fuv_zVYHqZfIPtwG7pBC-9FHpCcC9lKbkB_MNuKSq0H-13D75RcG9LO7Opa00CkgXR3pW45AbkaIzLz9ij4eBnFa60Z8uZIatJmbIowlDkeRML6lpMZ9pmC7bn6zuNhRPzf9rGmk0/s640/IMG_7925.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCp3fuv_zVYHqZfIPtwG7pBC-9FHpCcC9lKbkB_MNuKSq0H-13D75RcG9LO7Opa00CkgXR3pW45AbkaIzLz9ij4eBnFa60Z8uZIatJmbIowlDkeRML6lpMZ9pmC7bn6zuNhRPzf9rGmk0/s16000/IMG_7925.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgV__HvyXsQqyAOghetbinVp_vI3Vej0T_mjR2FpYSUd05I4iaIXUS6OhL6fS6t4ZeaW00vlTj5UdrgApHXUwVLK0A2YfEfQiXZtoHkGElTgreV3gZfuZ4BxzutRAs3Uegmj87UBnygU9M/s640/IMG_7926.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgV__HvyXsQqyAOghetbinVp_vI3Vej0T_mjR2FpYSUd05I4iaIXUS6OhL6fS6t4ZeaW00vlTj5UdrgApHXUwVLK0A2YfEfQiXZtoHkGElTgreV3gZfuZ4BxzutRAs3Uegmj87UBnygU9M/s16000/IMG_7926.jpg" /></a></div><p><b><b></b></b></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDOKpUuf5I40BP-JD20Gi6dyrpUTr-rc1R9f0cCukcIhHaso1PGdImiaZYIC3RXnmAZcq_Am7oF2LdMmonojkO4fQOYboqZ5uOu3T_ZX8lhuBDIRF8g8sfb4enfMsgt022HtwUtGC6tTE/s640/IMG_7914.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDOKpUuf5I40BP-JD20Gi6dyrpUTr-rc1R9f0cCukcIhHaso1PGdImiaZYIC3RXnmAZcq_Am7oF2LdMmonojkO4fQOYboqZ5uOu3T_ZX8lhuBDIRF8g8sfb4enfMsgt022HtwUtGC6tTE/s16000/IMG_7914.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLjdtppndCm2GLRt50rXYXwGKJB5YjmMnIQfPtEV-DyQVYZF_lz-lj2jHSpCMxz7YO9K1pyXlP9qmBNQfSLuyXHz0QsWPMu4syKr-rCt9H3PBnw9IZyLfWUnhkzu9fNiNn4B0Bp8Vq8gg/s640/IMG_7915.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLjdtppndCm2GLRt50rXYXwGKJB5YjmMnIQfPtEV-DyQVYZF_lz-lj2jHSpCMxz7YO9K1pyXlP9qmBNQfSLuyXHz0QsWPMu4syKr-rCt9H3PBnw9IZyLfWUnhkzu9fNiNn4B0Bp8Vq8gg/s16000/IMG_7915.jpg" /></a></div><br /><p></p><p><b><b>Armor</b><br /></b>The bracers, leg armor,
shoe armor, and pauldrons are foam floor mats. The half mask is craft
foam. The wrist plate of the bracers is attached to the rest of the
bracer with poly web so I can move my wrist. I used leather straps to
wrap my wrists. The palm strap is glued at each end with the other two
on the forearms using a tri-glide to tighten them down. I wish I had
made it velcro as I can't tighten the leather straps down one handed
using the tri-glides.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIUqBP6VrpicigfnYfHWcasYfSc3siEZtjJTZmHYUSmykcQpezhCQfzIoLj1w7BWEn6DftLNYGD_2vQPsHsFTNvZtj2TtkEHHgtLW4yiWW_zGg0vjT7UQFDtRxxXyNW6MQcZFNpGEQDxE/s640/IMG_7911.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIUqBP6VrpicigfnYfHWcasYfSc3siEZtjJTZmHYUSmykcQpezhCQfzIoLj1w7BWEn6DftLNYGD_2vQPsHsFTNvZtj2TtkEHHgtLW4yiWW_zGg0vjT7UQFDtRxxXyNW6MQcZFNpGEQDxE/s16000/IMG_7911.jpg" /></a></p><p>The leg armor is a clam-shell style with polyweb glued to both sides on the outside and polyweb with velcro on the inside.</p><p>I dyed a length of rope yellow for each side of the leg armor. It sits on the ledge in the front and I hot glued it in place. around the back it sits under the flare. I just did an overhand know on the outside. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlQaTX1fI0fQqhT5W4aRWTi2Q5oGRWACDaS2nKk4Uhpv0XxBw8xGbQWSuIzdtnUrSAyASCMZOp-9tYN7Wr_ZaczYYrjlAx1xTtl5jOCyIdscur2HoaGBPCpxOfMfrtCVv5asLZK6SQbVQ/s640/IMG_7908%255D.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlQaTX1fI0fQqhT5W4aRWTi2Q5oGRWACDaS2nKk4Uhpv0XxBw8xGbQWSuIzdtnUrSAyASCMZOp-9tYN7Wr_ZaczYYrjlAx1xTtl5jOCyIdscur2HoaGBPCpxOfMfrtCVv5asLZK6SQbVQ/s16000/IMG_7908%255D.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju0OHgsW4PStDgSrd-7Jd9dJk7CGOtU4jARuMlXhPTs9Dn8aZelXHOoJvfXSxeidqBFYsfcpoIBZbtjuUpiF2zfhJ3MOsEDgH_oji4o-kC1-2KrA-yVzuoydJ-RbU4ezfP_4FcPhFLrmw/s640/IMG_7909.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju0OHgsW4PStDgSrd-7Jd9dJk7CGOtU4jARuMlXhPTs9Dn8aZelXHOoJvfXSxeidqBFYsfcpoIBZbtjuUpiF2zfhJ3MOsEDgH_oji4o-kC1-2KrA-yVzuoydJ-RbU4ezfP_4FcPhFLrmw/s16000/IMG_7909.jpg" /></a></div><p></p><p>The
upper arm armor in reference photos attaches to the pauldrons, but I
just didn't like the look. It's a double layered foam armor with leather
straps and metal d-rings. I used poly web and velcro to strap it to my
arm. <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNGVQpY1vJQF2TZgMS4EEVWP7_9S0XzqbXtGLwQtEv8x3HTA8fXB6aZwv2tOo96CHuascaOp-Cj8urdHcMNmdFfd87qWWFRKg3_U6Nhv0L5eDu4VkxXO5AV-nt4-bf64I5JA96A-9sj0k/s640/IMG_7351.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNGVQpY1vJQF2TZgMS4EEVWP7_9S0XzqbXtGLwQtEv8x3HTA8fXB6aZwv2tOo96CHuascaOp-Cj8urdHcMNmdFfd87qWWFRKg3_U6Nhv0L5eDu4VkxXO5AV-nt4-bf64I5JA96A-9sj0k/s16000/IMG_7351.jpg" /></a> <br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjpxgMW57SPufXIVlkWr-AlTZN0sX1xJH-woWpz-sshAsEUx3GTTouOlUOX7Oeo_3GXkqNwtkQfQyhAbupSgy1OVlaDIyU2UNniWfkl_jraTsU1_xBbGEZThslkhqGRmY-GKhwmH7ohI4/s640/IMG_7918.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjpxgMW57SPufXIVlkWr-AlTZN0sX1xJH-woWpz-sshAsEUx3GTTouOlUOX7Oeo_3GXkqNwtkQfQyhAbupSgy1OVlaDIyU2UNniWfkl_jraTsU1_xBbGEZThslkhqGRmY-GKhwmH7ohI4/s16000/IMG_7918.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrAX95Wd-Fmjf9LAGCaLyuc9H-6uMjIqygcrdwbL6i9wOAmjQgsY8LodEavR2wuVqdA82NFNwCgOTQqe048492y9F67ucEfEn5qMMonzBxREL9-iO-UCb3cEK9kUfVG7a2OmVh5ZCMEVk/s640/IMG_7919.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrAX95Wd-Fmjf9LAGCaLyuc9H-6uMjIqygcrdwbL6i9wOAmjQgsY8LodEavR2wuVqdA82NFNwCgOTQqe048492y9F67ucEfEn5qMMonzBxREL9-iO-UCb3cEK9kUfVG7a2OmVh5ZCMEVk/s16000/IMG_7919.jpg" /></a></div><p>Shoe
armor is a plate on the top of the foot and heel. Elastic attaches them
front to back. Tension keeps it in place. I reinforced the strap to the
armor with craft foam. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE6eHO5s4WyvgZiOq4ZFDqeCO8OIupiP0pVPQ4EWV3_9mhHb3OoRh7697nJcOZ_pJAkrZxcZgInw2-gkhXB07_2btuztYvDCR5p8B70zwuGJzKYRP5U-g8LUXIGdOTjZHCRBdITs6t4dA/s640/IMG_7906.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE6eHO5s4WyvgZiOq4ZFDqeCO8OIupiP0pVPQ4EWV3_9mhHb3OoRh7697nJcOZ_pJAkrZxcZgInw2-gkhXB07_2btuztYvDCR5p8B70zwuGJzKYRP5U-g8LUXIGdOTjZHCRBdITs6t4dA/s16000/IMG_7906.jpg" /></a></div><p><b>Chain and Kunai</b><br />Scorpion's
spear is called a kunai. I bought galvanied chain from a big box store
and had it sand blasted. I sprayed it with flat black, turning it over
to try and get an even coat. Then I wiped it down with a rag. This gives
it a darker look that's uneven. It looks way better.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyS0r2Qv8QCGOVb0601kh34vE1pVboVTbhEx7u2wXOxvZtbo4BxR4PDSDipsZf54uRQnk6XgMT1flPls5ovlE-iQgsgqR4pImda3OAl_fG5fgcdAtkoYtHRKoOb4a-9mpdNcDASwjHIlA/s640/IMG_7850.jpg"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyS0r2Qv8QCGOVb0601kh34vE1pVboVTbhEx7u2wXOxvZtbo4BxR4PDSDipsZf54uRQnk6XgMT1flPls5ovlE-iQgsgqR4pImda3OAl_fG5fgcdAtkoYtHRKoOb4a-9mpdNcDASwjHIlA/s16000/IMG_7850.jpg" /></a></p><p>The kunai is
1/8" plywood. I made this start to finish including paint in fifteen
minutes as time was short. I cut the spear shape simultaneously out of
two piece of ply. Then slotted the top half of one and bottom half of
the other so they fit together. I glued them with wood glue, painted it
with primer, then misted it with black. I rubbed it with a glove finger
to give it some character. I drilled a hole in the end and used a
plastic chain link to attach the spear to the chain.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT1jyqqJVcL2Zv-a5eWtwFaNGBwXU249iJhB_19TErp392x_1-aMHhM-6PywzPwCO1ceQ5K3bfkhJp-0LuSJAKH3C2pXEzT26dCCCBe2wSqSHKbP7zM5rieMdDmbnVMboZX9Jdqa4fzLI/s640/IMG_7910.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT1jyqqJVcL2Zv-a5eWtwFaNGBwXU249iJhB_19TErp392x_1-aMHhM-6PywzPwCO1ceQ5K3bfkhJp-0LuSJAKH3C2pXEzT26dCCCBe2wSqSHKbP7zM5rieMdDmbnVMboZX9Jdqa4fzLI/s16000/IMG_7910.jpg" /></a></p><p><b>Pants and Shoes</b><br />I
bought these items. The shoes are wrestling shoes. I wish I had spent
more for ninja style shoes with a split toe. I searched for ninja pants
and these were listed. They lace up along the calf and are baggy above
creating the ninja look.</p><p>I dyed a 3" wide strip of yellow that wraps around the knee and attaches with velcro.<br /></p><p><b>Finish & Paint</b><br />All
foam gets heat treated before paint. A heat gun pointed at the foam for
a few seconds will do it. The foam will become a bit darker and develop
a sheen. This seals the foam so it absorbs less paint. You can burn the foam, so be careful.</p><p>Once the
foam is sealed spray the foam with Plasti-dip. It's a durable, flexible
base for the color. There are other options like thinning PVA glue
(white Elmer's glue). I've never tried it. I could have, and maybe should have,used acrylic caulk for the seams of
the half mask, but I was running out of time. None of the armor had
seams so it wasn't necessary. <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijylS4WNpWb6nAEgFbkCc-GeKKtwZSy5mZpv4_-8dWHNM_96pKt7pGSHuAwlquwD6vPZYJdhipPkQT5O4THDlfANy4tm08qWdY37XE4eeTSO7bnWbdWbwtQxhB65JR8ZD20jtgxWwDcL4/s640/IMG_7513.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijylS4WNpWb6nAEgFbkCc-GeKKtwZSy5mZpv4_-8dWHNM_96pKt7pGSHuAwlquwD6vPZYJdhipPkQT5O4THDlfANy4tm08qWdY37XE4eeTSO7bnWbdWbwtQxhB65JR8ZD20jtgxWwDcL4/s16000/IMG_7513.jpg" /></a></p><p>After the plasti-dip dried I
painted the armor was sprayed with metallic silver
and the half mask with metallic gold. Before that was fully dry I misted
flat black, white, and brown onto the surfaces. At first glance it
looks like nothing was added. The subtlety gives it a realistic look.
Otherwise it looks like a toy with a uniform surface.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDRTvE58EPD37MXyxPGdXc_EQv1sHzsJAnYuGmBTHPtQKgFIZQ1xiR6bK-8UGnH2D7M4M7ocCTW_9I4AyKqOuq8cUhuyyg_fLXZ2aVj26bBltIQZhmxxfW2aXCSDDcMMSmTUZTv_PUm00/s640/IMG_7518.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDRTvE58EPD37MXyxPGdXc_EQv1sHzsJAnYuGmBTHPtQKgFIZQ1xiR6bK-8UGnH2D7M4M7ocCTW_9I4AyKqOuq8cUhuyyg_fLXZ2aVj26bBltIQZhmxxfW2aXCSDDcMMSmTUZTv_PUm00/s16000/IMG_7518.jpg" /></a></div><p>I had
planned to
weather the armor but ran out of time. I would have used a oil black
wash as I like the effect better on silver for a metal texture. It gives
it a slightly darker tone, but it provides more of a realistic finish. I
would have wiped black paint across the surfaces, wiping it off with a
rag. This leaves paint in the cracks and crevices to give it a dirty or
used look.</p><p>Depending on your base coat and desired effect you may want to use acrylic which wipes off easier and won't change the color.<br /></p><p><b>Unbuilt Items</b><br />I
knew I wouldn't get to the tantos. I did a test run and reinforced and
reglued a few items. I wish I had time to go back and make the tabard
more realistic, adding the striping and edging.</p><p>My biggest
disappointment is the half mask. It looks like a bird or plague doctor.
It sticks out a bit too far coming off the nose. It doesn't match the reference very closely. I just didn't have time to
redo it, and shaping something with complex curves gets tricky. It's something that takes a few iterations to detail correctly. Weathering also would have provided it a lot of depth, dark colors in the corners and even some silver dry brush highlights.<br /></p><p>While I wanted to weather the armor, it doesn't look bad, but it would have been a nice detail <br /></p><p>I also wish I had bought ninja split toe shoes instead of wrestling shoes.<br /></p><b>Conclusion</b><br />The
shoulder pauldrons might be my favorite part. I love the complexity and
look. The braided cord took more time than anticipated, but it's a cool
detail. The skull mask came out great and the gloss black eye paint
blends with the lenses near seamlessly. The visibility is great in this
mask, which often isn't the case with my costumes.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghd-kSMftkMBmA8sIJO6JoydMYKN-dNiS_iPCklp9iwF325QgJB1NnuMH6BFxYUVCVucdtXdbmQ7ZxHqDzA_3Nh9LOJO6DYAuO1t2Iv4ZCqP_TKA6ztLngBOiBKDsygGcIxRKrCvgFRfA/s640/IMG_7876.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghd-kSMftkMBmA8sIJO6JoydMYKN-dNiS_iPCklp9iwF325QgJB1NnuMH6BFxYUVCVucdtXdbmQ7ZxHqDzA_3Nh9LOJO6DYAuO1t2Iv4ZCqP_TKA6ztLngBOiBKDsygGcIxRKrCvgFRfA/s320/IMG_7876.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMqsHchL5etAfdeo_7Yhw6VDDvfasM9T-QQIUtSNmQhBWT09u_m8hTgNtjPxoifdqTqY00yGcY6AYOpRXPQLXtLLaa3DIriCmZbrevSsAsXWYNGXHXpsQoTsohUcVjpfvFRkuJ4hm13OU/s640/IMG_7878.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMqsHchL5etAfdeo_7Yhw6VDDvfasM9T-QQIUtSNmQhBWT09u_m8hTgNtjPxoifdqTqY00yGcY6AYOpRXPQLXtLLaa3DIriCmZbrevSsAsXWYNGXHXpsQoTsohUcVjpfvFRkuJ4hm13OU/s320/IMG_7878.jpg" width="320" /></a></div><br /><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvyaodPk8aQqiFy6_XDXMvf6xcuqX5sJSU-YsZ87t7PfOz94ekMPqWSdCx8z_ATEFx5O3hck4QPEiFPHxv1egAhkU07TRgzjvtDwXvnEPaEc4nASYokMz6YhlSiAKDP6sKy4rf-p_gDMA/s640/IMG_7884.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvyaodPk8aQqiFy6_XDXMvf6xcuqX5sJSU-YsZ87t7PfOz94ekMPqWSdCx8z_ATEFx5O3hck4QPEiFPHxv1egAhkU07TRgzjvtDwXvnEPaEc4nASYokMz6YhlSiAKDP6sKy4rf-p_gDMA/s320/IMG_7884.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; 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text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJXTWPXzDxxOfdF5jc4PmOhup6w83d8QzswywTO8R5Ph8h7bC2YP_zX2GAQFLM2rrHxKS_KtjLJcZWbjss_8ePZFKsmnl26K326Z9DHY6FGO4trmFAgQogznsM96XKOJadhDK0J1kNUU0/s640/IMG_E7878.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJXTWPXzDxxOfdF5jc4PmOhup6w83d8QzswywTO8R5Ph8h7bC2YP_zX2GAQFLM2rrHxKS_KtjLJcZWbjss_8ePZFKsmnl26K326Z9DHY6FGO4trmFAgQogznsM96XKOJadhDK0J1kNUU0/s320/IMG_E7878.jpg" width="320" /></a></div>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-89810273482617466392021-09-10T02:00:00.082-04:002021-12-30T16:07:38.685-05:00How to Replace a Sliding Door<span face=""arial" , "helvetica" , sans-serif"><b>Replace a Sliding Door</b></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7fRxJ__9q8dI2G0GtmcZN3wbJQcDUXPfZdmB-3DT1O_bZa7q4TUyFCIMK0Y_A3MSI5sRMSRxitZ8D-aFXGx_0KEOCRjaIBmOMR9cp8BFeWkspNPJ2VRh0rex8BMGTAO9-KEDJ8eKVLPQ/s640/sLIDINGDOORyxx.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7fRxJ__9q8dI2G0GtmcZN3wbJQcDUXPfZdmB-3DT1O_bZa7q4TUyFCIMK0Y_A3MSI5sRMSRxitZ8D-aFXGx_0KEOCRjaIBmOMR9cp8BFeWkspNPJ2VRh0rex8BMGTAO9-KEDJ8eKVLPQ/s16000/sLIDINGDOORyxx.jpg" /></a><br />My sliding door is beyond repair. It's time to replace it.<br />
<a name='more'></a>
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<b>Purchase List:</b><br />
<div><a href="https://www.lowes.com/pd/ReliaBilt-Clear-Glass-White-Vinyl-Universal-Reversible-Double-Door-Sliding-Patio-Door-Common-72-in-x-80-in-Actual-70-75-in-x-79-5-in/4439395" target="_blank">(1) 72"x80" Sliding Door</a><br /></div>
<div><a href="https://amzn.to/3jpEODz" target="_blank">25' of 1/2" foam backer rod (paid link)</a></div>
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<a href="https://amzn.to/3gCeDaU" target="_blank">(2) tubes of door/window caulk (paid link)</a></div><div><a href="https://amzn.to/3Dns8Fc" target="_blank">(2) packs of tapered wood shims (paid link) </a></div><div><a href="https://amzn.to/3mELrno" target="_blank">(5) 2" coarse thread screws (paid link)</a><br /></div><div><a href="https://amzn.to/3sYz4Un" target="_blank">painters tape (paid link)</a><br /></div>
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<b>Total: $350</b></div>
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<br /></div>
<div>
<b>Tool List:</b></div>
<div>drill w/ 1/8" bit</div><div>box cutter to score shims, flanges, and cut backer rod<br />level</div><div>caulking gun<br /></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />The sliding door that came in the house didn't slide well, the handle had broken three times, and it didn't lock. I tried to replace the rollers, but the replacement rollers didn't quite fit such an old door. It helped, but it wasn't perfect.<br /> The new <a href="https://www.lowes.com/pd/ReliaBilt-Clear-Glass-White-Vinyl-Universal-Reversible-Double-Door-Sliding-Patio-Door-Common-72-in-x-80-in-Actual-70-75-in-x-79-5-in/4439395" target="_blank">Reliabuilt door</a> is a good door. I considered opting for the Energy Star certified door, but at nearly double the cost it only provided an additional 0.5 R value. One inch of foam offers 5 R value, so the upgrade wasn't worth it.</p><p>The most challenging aspect was getting the door from store to home. It's big and top heavy. It takes two people.</p><p><b>Video How To<br /></b></p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/WZtg7HraZ7k" width="320" youtube-src-id="WZtg7HraZ7k"></iframe></div><br /><span face=""arial" , "helvetica" , sans-serif"><b>Removing the Old Door</b></span><br />
I started by lifting the door rollers via screw and then lifting the sliding door out of the track. I installed tile floor a few years back. The tile is 1/8" of an inch taller than the door track which prevented me from lifting the door out.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3bfVAHuecgeQ0UIUXJ39VTcVEjfTnMdTBc3FDn2PUgNKi7u4jpA-JHJm0u3JJfIQk96iG_jKk52biwdR3OEj5WRlTWp9V3GNATx8D3D32G-kwtRYDxOnc7sk4T8yxUCot1PRJtsnbLnc/s640/slider06.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3bfVAHuecgeQ0UIUXJ39VTcVEjfTnMdTBc3FDn2PUgNKi7u4jpA-JHJm0u3JJfIQk96iG_jKk52biwdR3OEj5WRlTWp9V3GNATx8D3D32G-kwtRYDxOnc7sk4T8yxUCot1PRJtsnbLnc/s16000/slider06.jpg" /></a><p></p><div class="separator" style="clear: both; text-align: center;"></div><p>I removed six screws from the jamb. Some sliding doors have the jambs, head, and sill as separate pieces that lock into place. I thought this was constructed in that manner, but I couldn't separate the pieces. I ended up prying one of the jambs out enough to cut it with a hack saw. The frame was all one piece with the screws attaching the jamb, sill, and head concealed. I used a rubber mallet to knock the sliding door frame out of the rough opening and provide enough space to remove the sliding door.</p><p>The screws in the sill were rusted. I had to drill them out. Once the frame is removed use vice grips to remove the shaft of the screws in the sill if you had to drill them. <br /></p><p>Once removal was complete I vacuumed the opening.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Installing the New Door</b></span><br />The door is reversible. I had to remove the sliding door, flip the door frame over end and reinstall the door to get the correct orientation. To remove the door, lift the rollers and then lift the bottom out.<br />I screwed a 2x4 onto the top flange to prevent damage during the flip.The frame is the same on all four sides, so flipping the frame doesn't change anything about how the door operates. The door needs to be removed anyway to remove a plastic spacer between the door track and frame to prevent it from sliding around during transport. You will also need to remove the door track and filler panel and reinstall if you flip the door.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIXhlyB8I8d6HiUg5LHO3z8XQb6QewcTDPJDcAFL8Z0apNKT405zZnd6T_XHOk5UhfJbmq0l0-N-ulVUwydi3IdzEtHuF9_WZ86EGURBgTSTXbg5XXNoZ2DXfXvY1HYmSf5Az0mdFIYLM/s640/SlidingDoor01.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIXhlyB8I8d6HiUg5LHO3z8XQb6QewcTDPJDcAFL8Z0apNKT405zZnd6T_XHOk5UhfJbmq0l0-N-ulVUwydi3IdzEtHuF9_WZ86EGURBgTSTXbg5XXNoZ2DXfXvY1HYmSf5Az0mdFIYLM/s16000/SlidingDoor01.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I installed a 2x4 on the top by screwing through the tab before flipping the door.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZRMlgU9TdS8ib4rKWRwJk4gurI3BI4LTh_V_ZTTeaELWfbFZD0zmgze5lPKa2Rq1L3XVCtWgP_XlT49MvY2_3gqZJC9v2y_0MgNzgCj1mLizhnIkrQ8mXjjfK0l-66BiQZ4D0P41685o/s640/slider09.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZRMlgU9TdS8ib4rKWRwJk4gurI3BI4LTh_V_ZTTeaELWfbFZD0zmgze5lPKa2Rq1L3XVCtWgP_XlT49MvY2_3gqZJC9v2y_0MgNzgCj1mLizhnIkrQ8mXjjfK0l-66BiQZ4D0P41685o/s16000/slider09.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A pry bar will help remove the door track if flipping the door.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-yRTJbTIQNay9g7GA-fluuFX1Vj3Bb8sNgI4cY3sFd8tbRNQ7d84bMxTXHN51ejpxAczn10OwkCi8-WN_hjZfehP5wyroylYF9Lrh1HpID8JZzlcfD-WjZ58zl53es6QwjCx6p-kHSbg/s640/slider08.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-yRTJbTIQNay9g7GA-fluuFX1Vj3Bb8sNgI4cY3sFd8tbRNQ7d84bMxTXHN51ejpxAczn10OwkCi8-WN_hjZfehP5wyroylYF9Lrh1HpID8JZzlcfD-WjZ58zl53es6QwjCx6p-kHSbg/s16000/slider08.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">If you flip the door, the silver metal door track and white plastic trim piece <br />need to be removed and reinstalled.<br /></td></tr></tbody></table><p>For a replacement, you will need to cut off all four fins with a box cutter. Score them and snap them off. If this were a new door, you would leave the tabs, screwing through the fins and into the wall sheathing.<br />I put flashing on the wood sill, but since this is an interior door it's not a requirement. If this were an exterior door, I would be flashing all four sides of the frame, making sure to tie from exterior sheathing back into the interior. Flashing tape with flex tape at the corners would be the easiest and most efficient way to do that.<br /></p><p>The manufacturer recommends (2) screws per jamb, 6" from the head and sill. I installed (3) on the fixed door side, one at the top and bottom and one in the middle, as the latch is on the other and the latch uses (2) screws that are provided. The screws to install the door are not provided.<br /></p><p>First I made sure the sill was level, it was. Then I shimmed the door sides to space the door equally in the opening, then used the shims to make sure the door was plumb. You need shims at every screw. Overlap the shims by inserting them from each side so the thin end of one is at the thick end of the other. This provides a flat, solid surface to screw through. When you then slide one shim across the other, the thickness of the two shims remains equal. If you only put the shim through one side, the door will want to wobble or twist.<br />Pre-drill through the door jamb. Take extra time to make sure the screws are centered in the jamb and at matching distances from the head/sill for a cleaner look.</p><p>The manufacturer directs to NOT put screws in the sill and that screws in the header are optional.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP7pS4XWtjHbvKGoXBheMOTp6Yr5Wk-FqrK_ocE5gLbtvdE8kQnEqk0Ls8QLzIliEXXNNqT-Eh_LqiTihnWojMAgQ8TiSzNP01bxtTrllmJ6aFNRdUK4U4abo_MM0-Q7WOlA-FLvstV5g/s640/slider07.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP7pS4XWtjHbvKGoXBheMOTp6Yr5Wk-FqrK_ocE5gLbtvdE8kQnEqk0Ls8QLzIliEXXNNqT-Eh_LqiTihnWojMAgQ8TiSzNP01bxtTrllmJ6aFNRdUK4U4abo_MM0-Q7WOlA-FLvstV5g/s16000/slider07.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Door handle assembly.<br /></td></tr></tbody></table><p>Once the frame is installed, reinstall the door, head first. When adjusting the door rollers, pick the door up to reduce the tension on the rollers and to make it easier to lower the rollers.With the weight of the door on the rollers, they won't lower easily.</p><p>This door handle had a set of screws to mount the handle to the plate and then another set of screws going through the door to each side. With the handle installed, the door is usable, though the job isn't done.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Finishing Work</b></span><br />To finish the install, score and snap the shims. Make sure you score and snap them so that they don't extend past the door frame. Place backer rod between the door and rough opening around the entire perimeter on both sides. Backer rod fills gaps and ensures the caulk has an hour glass shape which promotes expansion and contraction. I had a 3/8" gap at each jamb, but a 1" gap at the header.</p><p>To temporarily close the header gap I cut up a pool noodle to fit until I could cut a wood filler piece.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFb4uiaq09hZ3GNkZ1RD0EKzwFtU4Pl1CQkACiSWT3GaC2hfiMwV_AekDzD2IsSVcDb0vQel92omJSN2N2_bDeY4kNyIjWuwQNzUO5bU54bEjS4Mt3QiLOhQ_Oi7XM4a5WOIiJ3VE7big/s640/slider05.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFb4uiaq09hZ3GNkZ1RD0EKzwFtU4Pl1CQkACiSWT3GaC2hfiMwV_AekDzD2IsSVcDb0vQel92omJSN2N2_bDeY4kNyIjWuwQNzUO5bU54bEjS4Mt3QiLOhQ_Oi7XM4a5WOIiJ3VE7big/s16000/slider05.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Pool noodle to temporarily fill the gap.<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4eHUzJM2IGXH8_FYKOIT9i6deL_bPIhxtnaqqG0gPVUgv8WF3vopkG6bfzbzlP8z4IyG2NeahOLkhgoGwWcZlEi0d7cHzX96EuISore62ZMSnwRoY7QzUXKH1ffEcehSnKOJt5q6RIr8/s640/SlidingDoor12.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4eHUzJM2IGXH8_FYKOIT9i6deL_bPIhxtnaqqG0gPVUgv8WF3vopkG6bfzbzlP8z4IyG2NeahOLkhgoGwWcZlEi0d7cHzX96EuISore62ZMSnwRoY7QzUXKH1ffEcehSnKOJt5q6RIr8/s16000/SlidingDoor12.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Glue up of the wood filler piece.<br /></td></tr></tbody></table><p>I cut 3 pieces of 3/16" plywood, glued them together and then glued them to the head to reduce the gap. I used shims to hold it in place to glue it to the head of the rough framing. I painted it to match the trim prior to install. </p><p>Once the backer rod is in place, use painters tape to mask out on each side for the caulk. This makes clean up MUCH easier. You also don't have to be as careful when initially caulking. <br />Cut the end of the caulk tube off and pull the end of the gun across the gap to caulk, as opposed as pushing the tip into the caulk as it dispenses. Wet a gloved finger and push the caulk into the gap as you drag your finger across the line to create a finished appearance. Add caulk as needed. Make sure the caulk fully fills the gap, there are no holes or voids, and that you have a smooth finish. Water helps in achieving a smooth finish.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtBJAhurTA_110eX7smoT2Byo69OZVxsfGHNxMJFyr6YEBBxZXnL_xPMaW_M5SwbvF_rHgC3JopOVk6RT_C5tcdZ6aDlOyX-ndH4czEIKKrA-Pt2S3Jjri2yocZMIEmxdVbsXo0gemtEo/s640/slider04.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtBJAhurTA_110eX7smoT2Byo69OZVxsfGHNxMJFyr6YEBBxZXnL_xPMaW_M5SwbvF_rHgC3JopOVk6RT_C5tcdZ6aDlOyX-ndH4czEIKKrA-Pt2S3Jjri2yocZMIEmxdVbsXo0gemtEo/s16000/slider04.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Backer rod in, and masking done for caulk.<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHK8KMLa-154KSGf5FSdte0jwo5SfLUugXZ0bd9Qf7U-ZCcFdlFbeHsydM5UqRQnORcH3k8-CF0D9QSZccr3fz_lNlsmiFLyczXsMbXH-P055BbeLYMEZ64O-WcJTXQ2oPA7aaO9ehiHc/s640/slider03.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHK8KMLa-154KSGf5FSdte0jwo5SfLUugXZ0bd9Qf7U-ZCcFdlFbeHsydM5UqRQnORcH3k8-CF0D9QSZccr3fz_lNlsmiFLyczXsMbXH-P055BbeLYMEZ64O-WcJTXQ2oPA7aaO9ehiHc/s16000/slider03.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Drag the end of the caulk gun across the gap.<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIH5cc789mKOsmigxAE1a5rPJr4G8xW-044YtfgtRt2KpvEk2HVh4FW2baBGuqNq1_wHn0WW1fTTdrEq67sNjfiZLJCm5ZWS7I3RXtzrk3j9lc0VuP0BkEPmBpPRbJgDvqyLpZdBpP7mY/s640/slider02.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIH5cc789mKOsmigxAE1a5rPJr4G8xW-044YtfgtRt2KpvEk2HVh4FW2baBGuqNq1_wHn0WW1fTTdrEq67sNjfiZLJCm5ZWS7I3RXtzrk3j9lc0VuP0BkEPmBpPRbJgDvqyLpZdBpP7mY/s16000/slider02.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Use a wet finger to smooth the caulk bead and press it into the gap.<br /></td></tr></tbody></table><p>Pull the tape off soon after you caulk. If you wait until the caulk dries you may pull your caulk bead up, or at least tear the edges.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span><br />This is a really nice door. I was impressed with the quality. It rolls smoothly with minimal effort. It's completely worth it. Install time can vary. My initial install time was three or four hours with most of that trying to figure out how to break down the existing frame. I went back the next day to caulk.</p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1YtXqg2qvg3ZpnnL3VpuqsG4chwZfgbWWXgY5JST6d_5DA4fl7JhcAwq8nXB7JGqqLBAu8Z2ijYWydNhPbSznXPyt4cbILEVhIAIrVZl8ONVnC3x0CmE1lhVsYACWn2_tZGbNOfgdjpg/s640/slider01.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1YtXqg2qvg3ZpnnL3VpuqsG4chwZfgbWWXgY5JST6d_5DA4fl7JhcAwq8nXB7JGqqLBAu8Z2ijYWydNhPbSznXPyt4cbILEVhIAIrVZl8ONVnC3x0CmE1lhVsYACWn2_tZGbNOfgdjpg/s16000/slider01.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">PVC door stop.<br /></td></tr></tbody></table>I modified the door stop from the previous door to fit this one. It's just 1" PVC with a keyslot hanger and a screw in the jamb to hang it up when not down. <br /><p></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-24094010942324275762021-09-03T02:00:00.018-04:002021-09-13T10:09:28.781-04:00Restore Faded Plastic Headlights and Taillights<span face=""arial" , "helvetica" , sans-serif"><b>Faded Plastic Restoration</b></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgh1Imilzs6fx0viW5rtTepvDyBP-wsVwDwN3zA5ayTZuw_Ue-Ysd0IX7GxeFHjP-HT81zHH_O2n1sg4o54LKMS4Z6lwBOzNQ0S7CEm9AvgpAAoYzp2Xw5YXX04_uYM3d83sWO2mbi-V0/s640/IMG_6898x.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgh1Imilzs6fx0viW5rtTepvDyBP-wsVwDwN3zA5ayTZuw_Ue-Ysd0IX7GxeFHjP-HT81zHH_O2n1sg4o54LKMS4Z6lwBOzNQ0S7CEm9AvgpAAoYzp2Xw5YXX04_uYM3d83sWO2mbi-V0/s16000/IMG_6898x.jpg" /></a><br />Plastic headlights will eventually fade and yellow. This is how to restore them to like new condition.<br />
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<b>Required Products:</b><br />
<div>400 or 600 grit wet or dry sandpaper<br /></div>
<div>2000 grit sandpaper<br /></div>
<div>Clear spray paint that is UV resistant<br /></div>
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<b>Total: $20</b></div>
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</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijti_A0cDfEHM7J85m6suesvbrgsAMrAbb5jVqthLWCZQ9EsrQpNxA1EwPszyX-UCG0DWsuNyUE1zs6XlJ2kBZSMbLt30dQDcaPKDGVeDQH_mpr5LEvlVnN_e359Ka6jo7CB6BPrvb6iE/s640/IMG_6895.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijti_A0cDfEHM7J85m6suesvbrgsAMrAbb5jVqthLWCZQ9EsrQpNxA1EwPszyX-UCG0DWsuNyUE1zs6XlJ2kBZSMbLt30dQDcaPKDGVeDQH_mpr5LEvlVnN_e359Ka6jo7CB6BPrvb6iE/s16000/IMG_6895.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Faded, oxidized plastic.<br /></td></tr></tbody></table><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />If you plastic headlights or taillights are flat, faded, or yellow this will restore them to like new condition.<br /><br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Preparation</b></span><br />If possible remove the lights from your car. This depends on how easy it is to do, but it will preempt the preparation of taping off the car to wet sand and masking it for clear coating.</p><p>If there is any rubber trim on the plastic you'll want to tape it off with masking tape so you don't sand it. <br /></p><p>First clean the lights with dish detergent while wearing gloves. You want to strip any oils or grease from the light. This ensures you don't grind dirt into the plastic during sanding. You don't want to touch the light with your bare hands as that will contaminate the lights.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Sanding</b></span><br />Wet sand with 400 or 600. This depends on how crusty the plastic is. Either will work, but it's preferable to go from 600 to 2000 to ensure you aren't left with sanding scratches. Keep the plastic wet as you sand so the sandpaper doesn't get clogged.<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbjplWp6FBx1WEHg_AybcjWrqzbnZ8Ei6qHEeKfCMr7SbL39o7kXRlCemts_EdJQMHNomRmAXRLVcMgN_FRA98XxdUEEuwCsg4n3HV8tNL6_UyGaTMdRLYFxNhekFcRQXUrq52-VqoYw0/s640/oblight.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbjplWp6FBx1WEHg_AybcjWrqzbnZ8Ei6qHEeKfCMr7SbL39o7kXRlCemts_EdJQMHNomRmAXRLVcMgN_FRA98XxdUEEuwCsg4n3HV8tNL6_UyGaTMdRLYFxNhekFcRQXUrq52-VqoYw0/s16000/oblight.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">After sanding. The surface is clearer, but the finish is flat.<br /></td></tr></tbody></table><br /></p><p>Keep sanding until you no longer see the water turning yellowish. This is the oxidized plastic. Once the water on the surface of the plastic looks relatively clear/white, rinse the plastic well. The plastic will have a dull finish. It should not be yellowish. If the plastic still has a yellow hue, you're not done sanding. Once the plastic has a dull finish and is rinsed well, move to 2000 grit sandpaper. You want to sand the plastic thoroughly so that all of the sand scratches from the 600 is removed. The plastic will have a dull finish, and it should.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Clear Coat</b></span><br />
Clean the light one more time with dish detergent to ensure there are no contaminants. If the light is still on your car, use trash bags to liberally mask off your car and around the light to avoid overspray. Make sure the light is completely dry before paint.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmDbfITLuK6H1vQMY-z1R6x-uRZGBPM_zVRmiArnik0XkHKUcnT12a-2hZnBN17nH99kVZNVWX2iLLn8KFUq9j-WZZTeQU37KTp_vkmBv-7hSym8hyYcGhqrHuQOfizz8D7uwi_0MvB0g/s640/IMG_6894.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmDbfITLuK6H1vQMY-z1R6x-uRZGBPM_zVRmiArnik0XkHKUcnT12a-2hZnBN17nH99kVZNVWX2iLLn8KFUq9j-WZZTeQU37KTp_vkmBv-7hSym8hyYcGhqrHuQOfizz8D7uwi_0MvB0g/s16000/IMG_6894.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">UV resistant clear coat provides a glossy finish and sun protection.<br /></td></tr></tbody></table><p>Start with a light mist coat. You will build up the paint as you spray successive coats. Each coat will be slightly heavier. Do at least three coats, I did four. On the last coat spray it a little thicker. The paint droplets from an orange peel type finish. You want to spray a little heavier to smooth out that finish, but not so heavy the paint runs.</p><p>If the paint runs, you will need to sand it with 2000 and respray. Somehow I had moisture on the surface of one of the lights. I realized this after the clear dried and I had one white cloudy spot. I used 600 to sand through the clear and remove the contaminant. Then I sanded with 2000 and resprayed.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Finish</b></span><br />If you removed the lights, it's time to reinstall. Check the paint can for handling instructions. This paint was dry enough to handle in an hour, fully cured at 24 hours. It took many years for the lights to look this bad. I hope with a UV resistant clear coat the finish will last many more years.<br /></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-90675478298673416212021-06-09T02:00:00.004-04:002021-06-09T02:00:00.216-04:00Those MoviePass Days<p><span face=""arial" , "helvetica" , sans-serif"><b>MoviePass Came and Went Quickly</b></span><br />
<br />For a glorious six months I could see as many movies as I wanted. It ended terribly, but at least I got my refund.
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</p><a name='more'></a><p>The FTC has<a href="https://mashable.com/article/moviepass-scam-ftc-complaint/" target="_blank"> filed a complaint</a> against MoviePass that it actively prevented customers from seeing movies. The company folded in 2019, but this was well known to anyone that was a subscriber.<br /></p><p>I don't know where I discovered MoviePass, probably on Reddit. In February 2018 I subscribed to MoviePass. The cost was $10 a month for one movie a day and you had to sign up for a year. I believe it was originally $100 a month, but they lowered the price in August 2018 to attract members. At $10, it wouldn't take long for me to earn my money back. Watching just two movies a month for a year would put me ahead at matinee prices. I ended up canceling in August as it was clear this company was going down in flames due to multiple aggressive changes to terms.<br /></p><p>While my local theaters weren't in the program a nicer theater near where I worked was I would go on Wednesdays around 4pm. Usually the theater would only have one or two other people at that time. A few movies I was the only one in the theater. I loved it and I even kept going once a month after MoviePass (prior to the pandemic=).<br /></p><p>To use MoviePass, you would open the app when in the vicinity of the theater. You couldn't confirm a movie unless you were at the location.</p><p>In April, the app required you to take a photo of your receipt. In July they introduced "peak pricing" which means they would charge you for movies in 'demand.'</p><p>At the end of July they started limiting access to movies. New release movies would be restricted and accessible movies would vary per day. Luckily at times I went my theater only had one employee that did tickets and concessions. I would buy whatever movie was available through the app then go see the movie I actually wanted to see.</p><p>In August they changed the plan to three movies a month instead of one a day, while still restricting access to new releases. They changed the unlimited plan I paid for to only three movies a month claiming their terms of service allowed it. <br /></p><p>I canceled, well I tried to cancel but magically my password wouldn't work and I couldn't get a new password. I had to contact customer support, but ultimately I canceled and got $56 back. I was highly surprised. I had written that off.<br /></p><p>I knew when I signed up this service was unsustainable. Everyone knew it. I hoped I could get my money's worth. If I watched twenty movies I'd break even. I ended up watching thirty-one movies over six months. The equivalent cost at matinee prices would be $155. I canceled and applied for a refund which was doubtful. Many people were having issues.</p><p>MoviePass was destined to fail, but it was a glorious run. It seemed their business model assumed people would use this like a gym membership by paying and never actually going. People like going to movies!<br />I'd never gone to a theater knowing I was goin to watch a bad movie. I would never willingly spend money on something bad, but with MoviePass it didn't matter. Each movie I watched made the cost per movie cheaper. The first movie I saw with the service was Black Panther, the last Alpha.<br /></p><p>I love movies, and I love going to a theater to see movies. It's even better when there's no one else there. MoviePass opened up a world to me and changed my behavior. I would go once a month to a movie after I canceled the service.<br /></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-52437033841008808262021-04-26T02:00:00.040-04:002021-07-16T11:33:11.900-04:00Adding a Dust Collection System<span style="font-family: arial;"><span face=""arial", "helvetica", sans-serif"><b>Dust Collection</b></span></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhxhiWdWqhJcYartHmzFQW6n_30MK5emuyxoNzxp3CYqpzY0cLXvNlAFkN_JsNd2IOBl8Br0-tcNDSAZpCB3hQOqtk6zDxcEwwtr0uj9X1LjvOltkzL8SyM-NKS410OXXjiK3XicuLz4o/s640/IMG_5184.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhxhiWdWqhJcYartHmzFQW6n_30MK5emuyxoNzxp3CYqpzY0cLXvNlAFkN_JsNd2IOBl8Br0-tcNDSAZpCB3hQOqtk6zDxcEwwtr0uj9X1LjvOltkzL8SyM-NKS410OXXjiK3XicuLz4o/s16000/IMG_5184.jpg" /></a><br />
After cleaning up my shop (and a lot of dust), I decided to add dust collection. A dust collection is composed of a motor and impeller that sucks dust into a collection bag. Each sawdust producing piece of equipment is connected to the impeller through pipes.<br />
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One of the big things I learned midway in this project is that if
you're adding dust collection, chances are you will need to put it on a
separate breaker. Since I was doing electrical work in the shop at that
point anyway, it wasn't a major issue.<br />
It also isn't likely to be an issue if you don't have any big pieces of equipment like a table saw. If you don't have any big equipment, it's unlikely you would be installing a dust collector anyway.<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIiIrujszqSZ6wToV7Qztac4XaJ6s-HJiXxXfDwp3NPcpeeRVZA-ovSxAhRzrY20FGF1JA4vET_SVAUNv0Zm9RkuStQ6JNZJ8zrveOmkWUhn_C68fE_EJdNDaZ0U5NBw5pQ8ZcBGr4OfQ/s1600/IMG_1226.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIiIrujszqSZ6wToV7Qztac4XaJ6s-HJiXxXfDwp3NPcpeeRVZA-ovSxAhRzrY20FGF1JA4vET_SVAUNv0Zm9RkuStQ6JNZJ8zrveOmkWUhn_C68fE_EJdNDaZ0U5NBw5pQ8ZcBGr4OfQ/s320/IMG_1226.JPG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Harbor Freight Collector<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;">
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I started with the <a href="https://www.harborfreight.com/2-hp-industrial-5-micron-dust-collector-97869.html" target="_blank">2 HP Harbor Freight dust collector</a>. A mandatory upgrade is the filter. Many people upgrade to a Rikon 60-200 impeller upgrade, but I didn't want to spend the $110 for it.<br />I did a lot of research in how to setup the piping. You want to maximize air flow which means as many straight runs and as few curves as possible. Any branches need to be wyes, not tees. I have a straight run of pipe running down the wall with a branch that goes up the wall and across the ceiling.</div><div>At any 90* turns you want to use two 45s and a straight run of pipe instead of a 90* elbow. <br /></div><div><br /></div><div>You want to minimize the use of flex pipe and use tapered reducers to equipment ports if possible.<br /></div>
<br />
<b>General Requirements:</b><br />
<ul>
<li><a href="https://www.harborfreight.com/2-hp-industrial-5-micron-dust-collector-97869.html" target="_blank">Harbor Freight 2 HP Dust Collector</a></li>
<li>Piping & connectors<br /></li>
<li>Blast Gates</li>
<li>Thien Baffle</li>
<li>Galvanized Trash Can </li>
<li>Wynn Filter Upgrade </li><li>$450 <br /></li>
</ul>
<b>Piping List (Specific to My Set up/Equipment):</b><br />
<ul>
<li>(3) sections of 10'-0" 4" <a href="https://www.homedepot.com/p/JM-eagle-4-in-x-10-ft-PVC-D2729-Sewer-and-Drain-Pipe-1610/202280933" target="_blank">PVC pipe </a></li>
<li>(10) <a href="https://www.homedepot.com/p/NDS-4-in-PVC-Sewer-and-Drain-45-Hub-x-Hub-x-Hub-Wye-4P08/100164403" target="_blank">4" PVC wye </a></li>
<li>(2) <a href="https://www.homedepot.com/p/NDS-4-in-PVC-Sewer-and-Drain-Cap-4P06/100172701" target="_blank">4" PVC end cap </a></li>
<li>(4) <a href="https://www.homedepot.com/p/NDS-4-in-PVC-45-Degree-H-x-H-Elbow-4P03/100111278" target="_blank">45* PVC elbow</a></li>
<li>(11) blast gates - DIY</li>
<li>(10) pipe clamps - DIY</li>
<li>5" galvanized pipe from impeller to bag (optional, I ended up using the HF flex pipe)<br /></li>
<li>Cost $125 </li>
</ul>
<b>Materials for Blast Gates (x11):</b><br />
<ul>
<li>PVC pipe cut to 2.5" sections (or a coupler depending on your setup)<br /></li>
<li>1/2" Plywood or MDF for the Gate Body</li>
<li>Smooth Hardboard for the blades, laminate, or MDF (I used 1/4" MDF)<br /></li>
<li>Cost- roughly $40 depending on how much scrap you have</li>
</ul>
<b>Materials for Thien Baffle:</b><br />
<ul>
<li>Plywood top and bottom (roughly 18"x18")</li>
<li>Plywood Pipe Port</li>
<li>PVC pipe</li>
<li>PVC Hub Coupling</li>
<li>Hardboard</li>
<li>(4) threaded rods</li>
<li>(16) washers</li>
<li>(16) nuts</li>
<li>Cost - $20-50 depending on how much scrap you have</li>
</ul>
<b>Materials for Equipment Hookups:</b><br />
<ul>
<li><a href="https://www.amazon.com/CLEAR-COLLECTION-PEACHTREE-WOODWORKING-PW375/dp/B0013EOTRW/ref=sr_1_23">(2) 4"x10' Flex Pipe</a></li>
<li>(3) <a href="https://www.homedepot.com/p/NDS-4-in-PVC-Sewer-and-Drain-45-Hub-x-Hub-x-Hub-Wye-4P08/100164403">4" Whyes</a></li>
<li>(5) <a href="https://www.homedepot.com/p/4-in-x-4-in-PVC-DWV-Hub-Closet-Flange-C4851HD4/100345759">4" PVC Flanges</a></li>
<li>Styrene to box out table saw, band saw, router</li>
<li>(3) <a href="https://www.harborfreight.com/4-inch-x-2-1-4-quarter-inch-hose-connector-96457.html" target="_blank">2.25" to 4" reducer</a></li><li>(1) <a href="https://www.amazon.com/2-1-Ultra-Flex-Clear-Vue-Hose/dp/B01M35BE8D/ref=sr_1_8?ie=UTF8&qid=1541768336&sr=8-8&keywords=dust+collection+hose" target="_blank">2.5" flex pipe</a> <br /></li>
<li><strike>(3) Vacuum Formed Linear Flanges</strike></li>
<li>(13) <a href="https://www.amazon.com/Stainless-Adjustable-Automotive-Mechanical-Applications/dp/B07PB9KWGZ/ref=sr_1_1">4" Worm Gear clamps</a></li><li>$60 </li></ul><p><b>Total Cost: $600 range depending on various factors </b><br /></p><ul>
</ul><p>
<span style="font-family: arial;"><b>Pipe</b></span><br />
The inlet of the HF collector is 5", so there is no reason to exceed that size pipe. There is debate as to whether the HF collector can provide sufficient air flow for 5". I selected 4" PVC pipe due to cost and availability. Use PVC sewer and drain pipe instead of the heavier, more expensive schedule 40 PVC. You want to maintain the 4" up to and including the machines if possible, though many machines simply can't fit a 4" line. Enlarge the ports of machines when possible. When you have to install a reducer, a tapered reducer is preferred to help airflow.<br />
At a few machines, band saw, router, table saw, I wanted two pickups. <span style="color: red;"><span style="color: black;">You want to use as little flex pipe as possible, but at the machine it's unavoidable. You need enough flex pipe to move the machine as well. For any 90* bend, use (2) 45* connections with a straight run in between. A 90* bend reduces air flow.</span></span></p><p><span style="color: red;"><span style="color: black;">Use wyes instead of tees, again to avoid 90* bends. My pipe height was dictated by counters. It's roughly at 42" above the floor.</span></span><br /><br /><span style="color: red;"><span style="color: black;">At each branch/Wye, you need blast gates to close loops and maximize air flow suction. I made my own gates. They are better as there is no track for dust to fill up and are much cheaper.</span></span><br />
<span style="color: red;"><span style="color: black;"><br /></span></span>
<span style="color: red;"><span style="color: black;">I also made my own pipe wall brackets out of 2x4s.</span></span></p><p><span style="color: red;"><span style="color: black;"><span style="color: red;"><span style="color: black;">It's recommended to fasten joints with screws rather than glue so you can open the system easily to dislodge jams. With my pipe brackets, everything stays in place. The only thing I might do is to caulk a joint if it appears to not be sealed well.</span></span> </span></span><br />
<span style="color: red;"><span style="color: black;"><br /></span></span>
<span style="font-family: arial;"><b>Filter Upgrade</b></span><br />I bought a <a href="https://wynnenv.com/woodworking-filters/">Wynn filter</a> for two hundred dollars. The out of the box HF filter woefully under performs. The Wynn filter drastically increases filter
surface area and will stop much finer particles.</p><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHefMrR30anHywj6r4pzMX-BngROP1Ho2D91xa97iJMALtYgWK8KaSZ5T2Sb4iPf-C7OzKmLB3vZDexE1BqldefTbD1U4xQ-xrmqS82Fm3O_tzDx-sji90Nz-sHpTvIUnrmQ9hLsq2eZw/s640/IMG_3313+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHefMrR30anHywj6r4pzMX-BngROP1Ho2D91xa97iJMALtYgWK8KaSZ5T2Sb4iPf-C7OzKmLB3vZDexE1BqldefTbD1U4xQ-xrmqS82Fm3O_tzDx-sji90Nz-sHpTvIUnrmQ9hLsq2eZw/s320/IMG_3313+copy.jpg" width="320" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijUHqZj0p1xVAMw6x191BckYMtitE074fFnlSZYJOdNfg9uIalYpSWNS67pJR-SHKTo2N151dyCRhyxY38GchbzQHfvMRhvFXadgPM6hvOvgmauwAHTzNmLTAGp0Br9myuHWZXZch2Qo0/s640/IMG_3314+copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijUHqZj0p1xVAMw6x191BckYMtitE074fFnlSZYJOdNfg9uIalYpSWNS67pJR-SHKTo2N151dyCRhyxY38GchbzQHfvMRhvFXadgPM6hvOvgmauwAHTzNmLTAGp0Br9myuHWZXZch2Qo0/s320/IMG_3314+copy.jpg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Flange</td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-4KHUj6h5IK3p352l03j2GRJtqSGGFCIvg5bo-gYJWdQVM6hRf5EpCmOzHma66TC03H0mVSU5A3Jbjdn02xeTu8frQYYcD2kirS7GJmwIpaEIpxT4jK9K0FueSGrFvELrtNiLAmPBGR4/s640/IMG_3315+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-4KHUj6h5IK3p352l03j2GRJtqSGGFCIvg5bo-gYJWdQVM6hRf5EpCmOzHma66TC03H0mVSU5A3Jbjdn02xeTu8frQYYcD2kirS7GJmwIpaEIpxT4jK9K0FueSGrFvELrtNiLAmPBGR4/s320/IMG_3315+copy.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc8yu8eUyLkczArZ8-n3yeVp59mWP7gABFWC7ksbCcKwiBqUC73GBsl-opZc5x4pT7JPnocKo9F7OjuidiK604Cpk8ENpTHTF1K3PBHGgJyfSZWJPEgmJ7LhVwgQj8zIpOI7XjfYFQEC8/s640/IMG_3318+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc8yu8eUyLkczArZ8-n3yeVp59mWP7gABFWC7ksbCcKwiBqUC73GBsl-opZc5x4pT7JPnocKo9F7OjuidiK604Cpk8ENpTHTF1K3PBHGgJyfSZWJPEgmJ7LhVwgQj8zIpOI7XjfYFQEC8/s320/IMG_3318+copy.jpg" width="320" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBlMfc-a67kawFtLcyjwP-loAhgGBomL2HTHV0minWHqv9Gjp5AYRdpwqViPIcBmw6Sm6G4xG0odC6-o07FwttNFHjHhIg6G-dnQFXn6vq526Ao5YrEI1CcYoc3KYZnceErDkOqsproG8/s640/IMG_3319+copy.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBlMfc-a67kawFtLcyjwP-loAhgGBomL2HTHV0minWHqv9Gjp5AYRdpwqViPIcBmw6Sm6G4xG0odC6-o07FwttNFHjHhIg6G-dnQFXn6vq526Ao5YrEI1CcYoc3KYZnceErDkOqsproG8/s320/IMG_3319+copy.jpg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Worm gear straps<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6tmRPGN_RgxajHYHmYJ_qEZGQt2JojzQq7B8S8qmD6zs4fU6-KPwvc5hpj6Ty_7yiAx7OsLMPAYgBYg_mMnIviVPivOyz5wdTOW7zQVfLbKnDGGmuzcunYkzUqApyM_iYL5_frPPdBXA/s640/IMG_3320+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6tmRPGN_RgxajHYHmYJ_qEZGQt2JojzQq7B8S8qmD6zs4fU6-KPwvc5hpj6Ty_7yiAx7OsLMPAYgBYg_mMnIviVPivOyz5wdTOW7zQVfLbKnDGGmuzcunYkzUqApyM_iYL5_frPPdBXA/s320/IMG_3320+copy.jpg" width="320" /></a></div>The pleated design increases surface area which increases flow. The Wynn filter is designed to retrofit to various dust collectors.</div><div>I cut out a plywood flange as the dust collector body slopes. I caulked the flange in place. The filter has worm gear straps that attach from the dust collector body to the filter. It's a neat design. You drill a hole for a screw and the bracket. The worm gear has hooks that attach to the bracket and to the metal guard on the filter.<br /></div><div><br /></div><div>To reduce the amount of dust that reaches the filter and to reduce any wood chips that could hit the impeller, you need a chip separator.<br /></div><p>
<span style="font-family: arial;"><b>Chip Separator/ Thien Baffle</b></span><br />
I built a <a href="http://www.jpthien.com/cy.htm">Thien baffle</a>. It separates chips and dust before they reach the impeller and filter. A clean filter maximizes air flow. The baffle is placed inline before the impeller, with the baffle mounted to a trash can to collect chips/dust. Read my <a href="https://withwardworks.blogspot.com/2019/03/building-thien-baffle-for-dust.html">how to</a> for the details.<br /><br />
My 4" PVC pipe runs right into the Thien baffle, no turns. I wanted to
maintain airflow. I remounted the HF impeller directly on top of
the baffle in a top hat configuration. I used the supplied HF pipe to
connect the impeller to the collector bag in a straight run that is ~4" long, avoiding the longer curve of the out of the box setup.<br />
The trash can is mounted on blocks to get it to the right height that matches my pipe which had to clear the counter.<br />
<br />
To make the baffle, I built a circle cutting jig out of scrap. See <a href="https://withwardworks.blogspot.com/2019/03/router-circle-cutting-jig.html">my how to</a>. <br />
<br />
The trash can has a 17" diameter. The baffle is roughly the same. With a
1.5" interior slot. The inside clear height is 4.75". </p><p>I considered a Thien baffle and a cyclone. Based on space and anecdotal evidence I went with the Thien.<br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtsx8dionICVRNaReJnFeMG7v7wvJkrDEEdSGxaAFArzz-WYCa5CAvdXwVVjVOOcWkhgbKzwEn_HlAUEk0fPDEc_DEvR-30bI7UtnMAiFdwg-eymhQVbGEGe13Rhu-BHAKiIi2RJGxfZQ/s1600/IMG_1595.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtsx8dionICVRNaReJnFeMG7v7wvJkrDEEdSGxaAFArzz-WYCa5CAvdXwVVjVOOcWkhgbKzwEn_HlAUEk0fPDEc_DEvR-30bI7UtnMAiFdwg-eymhQVbGEGe13Rhu-BHAKiIi2RJGxfZQ/s320/IMG_1595.JPG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Motor, baffle, trash can<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;">
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<p><span style="font-family: arial;"><b>Grounding</b></span><br />
The following is based on my research. I haven't installed any grounding yet. Whether I do depends on whether/how much I get shocked. I'm not worried about a fire with my setup.<br />A static ground for non-conductive duct work can prevent static-charge
buildup. At a home shop it's more for comfort and to avoid small shocks. It's unlikely static build up will start a fire. To install one, simply run a wire along
or around the pipe. Insulated or
un-insulated 18- or 20-gauge copper wire, either solid or stranded, works
fine. At pipe joints, leave slack in the wire or install bayonet
connectors to facilitate opening the system in
case of a clog.<br />
Run a ground wire along each branch, and splice
each into the main wire. Connect the ground wire's conductor to the dust
collector's metal frame or housing. The other end should extend to the
outlet port on the tool, but it doesn't need to connect to anything,
except to keep it in place. The wire acts as an antenna rather than
a conductor in a circuit.<br />
<br />
If you use coarse screws for PVC connections, this also allows for tying in grounding.<br />
<br />
<span style="font-family: arial;"><b>Pipe Brackets</b></span><br />
The brackets are made from 2x4s with a bracket roughly every 48". I sketched a shape across (2) 2x4s and then cut them out on a band saw. I then sanded them to smooth out the cuts and smoothed them with spackle. I drilled a hole dead center to mount to the wall and two more to attach the clamp to the base. Then I painted them. Make sure that if you use masonry anchors, the screws are long enough to fully engage the anchor. That either requires longer screws or the screw to be recessed in the bracket.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5kaUkcfpju5jEsJw06al2xL4F63nCpffNCQNdXGFcqQZBIG5k-j7I-x2D7ksdOxzIV1w0Ht1IaN8FYFGyjCE-SicH-zvkWr7e069SGMvmBuV1LnglxztaBEghSjGIrjxAFB9L2IHmbyM/s1600/IMG_1600.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5kaUkcfpju5jEsJw06al2xL4F63nCpffNCQNdXGFcqQZBIG5k-j7I-x2D7ksdOxzIV1w0Ht1IaN8FYFGyjCE-SicH-zvkWr7e069SGMvmBuV1LnglxztaBEghSjGIrjxAFB9L2IHmbyM/s320/IMG_1600.JPG" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Make sure the screw is long enough to fully<br />engage the anchor.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;">
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<span style="font-family: arial;"><b>Installation</b></span><br />
I had a few restrictions. I wanted the system in a corner that was only 18" wide and had a garage door swing arm in the space. This meant the filter/bag could not fit in the corner. To make this work I needed the trash can to fit in the corner. I opted for a galvanized trash can with concerns a plastic one could collapse.<br />
<br />My pipe ran attached to the wall, which meant the Thien baffle inlet had to be against the wall. The pipe had to be higher than 36" to clear my counter, which meant the Thien baffle had to be above 36". That dictated the trash can height which would needed a 10.5" riser. The motor mounted to the top of the baffle dicated a riser for the bag/filter body. so that the impeller housing outlet lined up with the bag/filter inlet. </p><p>I used masonry anchors to attached 3/4" plywood to the wall to mount the motor. I bought longer screws as the ones that came with the anchors weren't long enough to go through the plywood and fully engage the anchor.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXRJHStY1eFOOGs-c0Qg_wkZiPPuYK-25QYnv8xmqx5K2OZ39hCsYYjzEb-ma2XWY0LxzLX4XYjWBt3UDTcjHExjTBGV9xif-M-c219i1zGgR0g7ghULz4f7ES-JWiJ7UMpLHuISvnTLU/s640/IMG_5065.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXRJHStY1eFOOGs-c0Qg_wkZiPPuYK-25QYnv8xmqx5K2OZ39hCsYYjzEb-ma2XWY0LxzLX4XYjWBt3UDTcjHExjTBGV9xif-M-c219i1zGgR0g7ghULz4f7ES-JWiJ7UMpLHuISvnTLU/s320/IMG_5065.jpg" width="320" /></a></div><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGuBpLjTQzmaf9qw0EbZWgphLCaRrth1IBX2RzpLqezb2a-TuIOr4Z1Y3mYMk_ivnzC08lp6KuAsyxNzkwytgKBMOH7Bh90G6Z6SsohG_eDmosGF2wL2cE9UxJeuXvXW01oSnTEgxOqWw/s640/IMG_5063.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGuBpLjTQzmaf9qw0EbZWgphLCaRrth1IBX2RzpLqezb2a-TuIOr4Z1Y3mYMk_ivnzC08lp6KuAsyxNzkwytgKBMOH7Bh90G6Z6SsohG_eDmosGF2wL2cE9UxJeuXvXW01oSnTEgxOqWw/s320/IMG_5063.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Bolt heads need to be recessed since this is the back<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbtZ7bOPRzGC_ZIaEXqAdZc-9v_QmUK1YfVwaw_6Ga9PUDPdTHzEHta9TYDMavzYDMYDRZGxrurNsHxAFSl40FZxt8rt6C8gFnv3ENmWznusC3eWD52rqZqcEzsIN-cB-UM6ftWY2Tok8/s640/IMG_5066.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbtZ7bOPRzGC_ZIaEXqAdZc-9v_QmUK1YfVwaw_6Ga9PUDPdTHzEHta9TYDMavzYDMYDRZGxrurNsHxAFSl40FZxt8rt6C8gFnv3ENmWznusC3eWD52rqZqcEzsIN-cB-UM6ftWY2Tok8/s320/IMG_5066.jpg" width="320" /></a></div><p></p><p>The Thien baffle hangs from the motor, I used scrap metal channel and threaded rod to create a clamp.<br /></p><div class="separator" style="clear: both; text-align: center;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE6ap1dVaFRt9O2EcTaQee6Mkc5LsfDBdoEgkBM9h-Stk-ktaZZeWIGE7IWD9sX1C-OQNnc0I-C1aJg70F8MPGokiAbQtF4yU3DOgqIC4uxbbtE883lEg3rOG4nnt24iIYvJZDhyphenhyphenLllH0/s640/IMG_5179.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE6ap1dVaFRt9O2EcTaQee6Mkc5LsfDBdoEgkBM9h-Stk-ktaZZeWIGE7IWD9sX1C-OQNnc0I-C1aJg70F8MPGokiAbQtF4yU3DOgqIC4uxbbtE883lEg3rOG4nnt24iIYvJZDhyphenhyphenLllH0/s320/IMG_5179.jpg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Mock up with baffle clamped to motor<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg1hMpj9iDH85gud1U_W6eRuAr2X8WLqH8QPKfIL97K_Vo2GcgDJsPRa8LXEPD1qLG5WxRoLfGPTgbxOG5He2XT-GHy3-Vb59HxesFgnABIhDwh-yRDPSZdqpG998WH0lZtWyNXkzd8LY/s640/IMG_5180.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg1hMpj9iDH85gud1U_W6eRuAr2X8WLqH8QPKfIL97K_Vo2GcgDJsPRa8LXEPD1qLG5WxRoLfGPTgbxOG5He2XT-GHy3-Vb59HxesFgnABIhDwh-yRDPSZdqpG998WH0lZtWyNXkzd8LY/s320/IMG_5180.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioeon8NIdbVpE8KwxI7oyybDDZRyo0sKU7tN5cnivq5eDaoFj6SqHdS5xm9FJuD6py_WC-52kFxHQzQlPuLGoKW0j57_0OA8LE7f-_Hww8EC36BAiOmNpxHbit_fF-867CUpHcc5RQtUQ/s640/IMG_5181.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioeon8NIdbVpE8KwxI7oyybDDZRyo0sKU7tN5cnivq5eDaoFj6SqHdS5xm9FJuD6py_WC-52kFxHQzQlPuLGoKW0j57_0OA8LE7f-_Hww8EC36BAiOmNpxHbit_fF-867CUpHcc5RQtUQ/s320/IMG_5181.jpg" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXD9Ht0eHzlyIJpMfEPe-6mEu6mTCz-Do5PWb-9yMGXsLKHiDzQMmvdYKBlYToNbJTRltFQ6Eos1kr_ddCEva5cYiFrqBeKs1_3NT1sR74IwBOF7Lgx7Ddwax7sszmKnm5LZTq0pac0fw/s640/IMG_5182.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXD9Ht0eHzlyIJpMfEPe-6mEu6mTCz-Do5PWb-9yMGXsLKHiDzQMmvdYKBlYToNbJTRltFQ6Eos1kr_ddCEva5cYiFrqBeKs1_3NT1sR74IwBOF7Lgx7Ddwax7sszmKnm5LZTq0pac0fw/s320/IMG_5182.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Recesses to mount to the bottom of the<br />HF platform.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuQNsXJMcSMLkWZQiorgF66YgEWGhKCuCJMTkUIXGoswI4dY3P2wGAR1OR5lgMv9YkcYxa87jlbzkzDNX3GOTh-RTnP8M1vLmoFx27zwCnYf015lGb0c34F4qnohj0Vdk7_Zk-mgbYC1I/s640/IMG_5183.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuQNsXJMcSMLkWZQiorgF66YgEWGhKCuCJMTkUIXGoswI4dY3P2wGAR1OR5lgMv9YkcYxa87jlbzkzDNX3GOTh-RTnP8M1vLmoFx27zwCnYf015lGb0c34F4qnohj0Vdk7_Zk-mgbYC1I/s320/IMG_5183.jpg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Platform lift<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhxhiWdWqhJcYartHmzFQW6n_30MK5emuyxoNzxp3CYqpzY0cLXvNlAFkN_JsNd2IOBl8Br0-tcNDSAZpCB3hQOqtk6zDxcEwwtr0uj9X1LjvOltkzL8SyM-NKS410OXXjiK3XicuLz4o/s640/IMG_5184.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhxhiWdWqhJcYartHmzFQW6n_30MK5emuyxoNzxp3CYqpzY0cLXvNlAFkN_JsNd2IOBl8Br0-tcNDSAZpCB3hQOqtk6zDxcEwwtr0uj9X1LjvOltkzL8SyM-NKS410OXXjiK3XicuLz4o/s320/IMG_5184.jpg" width="320" /></a></div><div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDp1gxr_dUz8iNREDWYUaHO2RjSUfi47bfcJlKwVZChH7ICoL6se8C87gqX-4MYAkAW1tqWVd1v-yCyGu37oZ0aM50hDj6B8KDXQvCzmNXo6kcJCDblBVW8KfZ_SBygIVIxhBAXW9PFJ4/s640/IMG_5185.jpg"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDp1gxr_dUz8iNREDWYUaHO2RjSUfi47bfcJlKwVZChH7ICoL6se8C87gqX-4MYAkAW1tqWVd1v-yCyGu37oZ0aM50hDj6B8KDXQvCzmNXo6kcJCDblBVW8KfZ_SBygIVIxhBAXW9PFJ4/s320/IMG_5185.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlvPYxgD3p6CL8kSrXRmhFwQvNqDLjxlnVDlY55Kr_gcLJQWa_I5bhY2657D6Rj32v8RzAFuw25TAE0hS52tsM7rb70Kn0_xXljHo3dkNp3QIa80VPKuvH75bVoItXo8zh8u5Yoe03kb8/s640/IMG_5186.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlvPYxgD3p6CL8kSrXRmhFwQvNqDLjxlnVDlY55Kr_gcLJQWa_I5bhY2657D6Rj32v8RzAFuw25TAE0hS52tsM7rb70Kn0_xXljHo3dkNp3QIa80VPKuvH75bVoItXo8zh8u5Yoe03kb8/s320/IMG_5186.jpg" width="320" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWicLAa-oxKqZUNVeKUiVbJWuv87o9S7F9FixjQ3LaQ1bne8aEI5oSqVpctiG1UbrIIGaAG5cCSeLg-L1-Ax2ev6L3jq0gmMz8TR_aaLGJUdHy7oAcTzdN26cGK4lmmH8R3G-TqfyqWP8/s640/IMG_5187.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWicLAa-oxKqZUNVeKUiVbJWuv87o9S7F9FixjQ3LaQ1bne8aEI5oSqVpctiG1UbrIIGaAG5cCSeLg-L1-Ax2ev6L3jq0gmMz8TR_aaLGJUdHy7oAcTzdN26cGK4lmmH8R3G-TqfyqWP8/s320/IMG_5187.jpg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Scissor jack trash can lift</td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO1N0qDOjYHV0l2gs65O9a1lHi61LyBdkzjmazlnjlTP1Wju_W25GWeZUNC8IQojt_sBjTZL2QlbKfOLu6xdTGTmFSqwPwX9TEjemfeySKuKR__a3shmDo1dg5bDK3gygDbc5uCyhojAs/s640/IMG_5467.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhO1N0qDOjYHV0l2gs65O9a1lHi61LyBdkzjmazlnjlTP1Wju_W25GWeZUNC8IQojt_sBjTZL2QlbKfOLu6xdTGTmFSqwPwX9TEjemfeySKuKR__a3shmDo1dg5bDK3gygDbc5uCyhojAs/s320/IMG_5467.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBd42TdG-dtouWVELlD2zVRFlG0I8_x7v1B_K4El846qeOfpWRQo8D68vPtXirexC2KtJA7FUGnIi4HwJVKwFzeBY_x22srBCY8aBMYExxLxDIAaW7bcbctH8vhAc1klv390iR7cDB6Wc/s640/IMG_5468.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBd42TdG-dtouWVELlD2zVRFlG0I8_x7v1B_K4El846qeOfpWRQo8D68vPtXirexC2KtJA7FUGnIi4HwJVKwFzeBY_x22srBCY8aBMYExxLxDIAaW7bcbctH8vhAc1klv390iR7cDB6Wc/s320/IMG_5468.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHV-UGPBJLPPkO-YXFKTwivDgb2HodMW6NSjnLRrkkgH2aHuDcoYLf8aPITUQutM7rhlmCrxCrvZm7KzqzXUXtOFLxHb9xAwgZqh1J1KNwb7qwyre9PcGnQ_M9HQ6m23uILZ2KK8TtvQA/s640/IMG_5469.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHV-UGPBJLPPkO-YXFKTwivDgb2HodMW6NSjnLRrkkgH2aHuDcoYLf8aPITUQutM7rhlmCrxCrvZm7KzqzXUXtOFLxHb9xAwgZqh1J1KNwb7qwyre9PcGnQ_M9HQ6m23uILZ2KK8TtvQA/s320/IMG_5469.jpg" width="320" /></a></div><a href="https://www.reddit.com/r/harborfreight/comments/9u053c/love_my_new_hf_2hp_dust_collector_with_added/" target="_blank"><br /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAz_qYLaw74em4dzH2KC5koo_pzXmfFKieD5gRbGRW9wymH4HPW3bpN8k3b_5lr3a7q2hcmt_-jdv9kqgSKiHhFR3uThisDjEO5Y1DSNbKTF4GGwLVIh_nFS1zjL1CoowypKF1X77c0Rk/s640/IMG_5073.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAz_qYLaw74em4dzH2KC5koo_pzXmfFKieD5gRbGRW9wymH4HPW3bpN8k3b_5lr3a7q2hcmt_-jdv9kqgSKiHhFR3uThisDjEO5Y1DSNbKTF4GGwLVIh_nFS1zjL1CoowypKF1X77c0Rk/s320/IMG_5073.jpg" width="320" /></a></div><p>I had to raise the filter/bag bracket to make all this work. I add 2x6 blocks with a 1" deck board topper between the stock base and casters. I did have to drill out for bolts and bracing on the existing platform.<br />
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To dump the trash can, I bolted 3/4" plywood to the smallest scissor jack I had on hand. Lowering the jack lowers the trash can from the Thien baffle, allowing me to dump it. The plywood is cut round with a 1/4" channel for the trash can bottom edge to sit into for stability.<br />
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I put the trash can and impeller in place, a mock up to start cutting pipe. I went one piece at a time, figuring out the best place for the wye. The process went quickly. I did not caulk any joints yet, I want to make sure everything is in the right spot. That will be the last step, if necessary.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgypy2pTK7-EYipmum41dhylQhEFSzPQfnKv9-XqiY2q1aJYOZYzTzjb9WD3cuSFVIzdli2DpKzvWINTNfcL75HeKTCZsF0BGKKbMyhhUgiQ5M4eaS2uuV0hj1I4z00v4qkNgzIJrKJeWY/s1600/IMG_1757.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgypy2pTK7-EYipmum41dhylQhEFSzPQfnKv9-XqiY2q1aJYOZYzTzjb9WD3cuSFVIzdli2DpKzvWINTNfcL75HeKTCZsF0BGKKbMyhhUgiQ5M4eaS2uuV0hj1I4z00v4qkNgzIJrKJeWY/s320/IMG_1757.JPG" width="320" /></a><br /></div><p><span style="font-family: arial;"><span face=""arial", "helvetica", sans-serif"><b>Blast Gates</b></span></span><br />
Blast gates restrict air flow to one tool, otherwise you wouldn't get enough suction. Gates are made from 1/2" MDF as it's cheap and smooth. I need 11 for my set up. <a href="https://withwardworks.blogspot.com/2019/04/making-blast-gates-for-dust-collection.html">Here is a tutorial</a> on how to make your own blast gates.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieQDR_mPvf4LgMC1O6K9wyihN2dqx7b2jmrRP47pwr3-fYKd5wo95GRSj3dPLPewGutS075AvLlKxFC3poX9MONJLXRsmO6nK0z_h4bzn0i0KU_X-LQd_GFPtIgeeIujDXVi988dPeWnQ/s640/IMG_5373.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieQDR_mPvf4LgMC1O6K9wyihN2dqx7b2jmrRP47pwr3-fYKd5wo95GRSj3dPLPewGutS075AvLlKxFC3poX9MONJLXRsmO6nK0z_h4bzn0i0KU_X-LQd_GFPtIgeeIujDXVi988dPeWnQ/s16000/IMG_5373.jpg" /></a></p><p>I've got a blast gate at each piece of equipment and where my piping branches from wall up to the ceiling. I located blast gates as close to the main run as possible. My goal is always to reduce line length or effective line length when possible.<br /></p><p>Once the gates are in place, caulk all the joints. You want to stop any air leakage to maximize efficiency. I have a ~2.5" piece of 4" PVC on each side of the gate. At a few gates I have a 4" to 2.25" adapter caulked into the gate. You want to caulk last in case you need to move/change/undo the layout. You could get away without caulking the joints unless you notice suction.</p><div><span style="font-family: arial;"><b>
Connecting Equipment</b></span></div><div>Each piece of equipment has a different size port, or none at all.</div><div>I boxed in the table saw with plastic and added a pvc floor flange to one side. <br /></div><div>I also boxed in my router table and added a PVC flange. I was going to split the pipe to collect from the base and top of the router table, but didn't have the space.</div><div>I also created a port on the band saw. I didn't box out the band saw as the pipe runs almost all the way to the blade. I boxed out the other equipment to increase suction at the blade.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8nmOVAMEJ2xCm8JyoVnFvayNuONbRrvBDOkfyJvAg8uI61ezJe0p_GbH3myJyyURXGiULmNAB3qThcgMbvLB4aJ-hKOwOSE4gOb9Jmk_GjrhwHeh7sLZ7iiEP_rgYhlfhDp0AYJeJSkA/s640/IMG_4996.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8nmOVAMEJ2xCm8JyoVnFvayNuONbRrvBDOkfyJvAg8uI61ezJe0p_GbH3myJyyURXGiULmNAB3qThcgMbvLB4aJ-hKOwOSE4gOb9Jmk_GjrhwHeh7sLZ7iiEP_rgYhlfhDp0AYJeJSkA/s320/IMG_4996.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtCX40c6o8kMRwHW66BKHoFN_CUSs2-gKj7P5uBNl_0tJ-W-HsJVMg-hoxlgW37SNjDBQSm635CxKZJuoQskdNU0nw7q3WRuoZY7v9csUYH0SdgudpKcm9ce0MDSB6sxBZHxH8rQD9K7g/s640/IMG_5056.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtCX40c6o8kMRwHW66BKHoFN_CUSs2-gKj7P5uBNl_0tJ-W-HsJVMg-hoxlgW37SNjDBQSm635CxKZJuoQskdNU0nw7q3WRuoZY7v9csUYH0SdgudpKcm9ce0MDSB6sxBZHxH8rQD9K7g/s320/IMG_5056.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPX6miN8vJmZsJzpHPh9bMrqgBJwkcr1dUyqpSfrekcassFrjiaJNI58sllDkZAI7-hWMB0QhUdzNTREdnIYswa189cyeZ-Xa-MCr4rHshfX2uuE64Grp9ugXDwOVQkxdfzdioGtGpRdE/s640/IMG_5470.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPX6miN8vJmZsJzpHPh9bMrqgBJwkcr1dUyqpSfrekcassFrjiaJNI58sllDkZAI7-hWMB0QhUdzNTREdnIYswa189cyeZ-Xa-MCr4rHshfX2uuE64Grp9ugXDwOVQkxdfzdioGtGpRdE/s320/IMG_5470.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixQKvDwKyZEYSp-N4YxTTFA0H0hFfG-yNM6S_kbpqD1j9-ysyF8mg7WQ75nO0ByN_WUiZd2St0yUkYWs-9U_zGH4BhOszcn9qkNwNdAtUOF16H1flZrN3dwlS_PnZGwno638JfpzwyApI/s640/IMG_5471.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixQKvDwKyZEYSp-N4YxTTFA0H0hFfG-yNM6S_kbpqD1j9-ysyF8mg7WQ75nO0ByN_WUiZd2St0yUkYWs-9U_zGH4BhOszcn9qkNwNdAtUOF16H1flZrN3dwlS_PnZGwno638JfpzwyApI/s320/IMG_5471.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNzb3hMnupHC5EMVOgcGmr6orAi9rZVKkyl6_KMGuDBnpSpx2aTNyB5x0kt0vDoDSemX_ehx-2jphNViDcGcz8kQA45BiC0QP-m-EwnqSYDHkJJ3FD25l6yRxnxTM_JXHQEV7NVEHXp9U/s640/IMG_5472.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNzb3hMnupHC5EMVOgcGmr6orAi9rZVKkyl6_KMGuDBnpSpx2aTNyB5x0kt0vDoDSemX_ehx-2jphNViDcGcz8kQA45BiC0QP-m-EwnqSYDHkJJ3FD25l6yRxnxTM_JXHQEV7NVEHXp9U/s320/IMG_5472.jpg" width="320" /></a></div></div><div><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEio5Mjf_cFOf29_cYtgrkdU4KhJWAPYbLXNKZEgRzysLXOvdsnNEfoT_pbvS8yUuXqxJW8pa6XibsZ_NYjrwrx_kNI9BrQZ0-riozA7yqTzFSkJ2wCWmCEBNd31iHIuLNeYNz-uvvg4vKU/s640/IMG_5473.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEio5Mjf_cFOf29_cYtgrkdU4KhJWAPYbLXNKZEgRzysLXOvdsnNEfoT_pbvS8yUuXqxJW8pa6XibsZ_NYjrwrx_kNI9BrQZ0-riozA7yqTzFSkJ2wCWmCEBNd31iHIuLNeYNz-uvvg4vKU/s320/IMG_5473.jpg" width="320" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The opening is lined with EVA foam so the metal<br />doesn't cut the PVC pipe.<br /></td></tr></tbody></table><br /><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8v_BilokkmdcDLKpwycCjzPalDd85SLfs8jrrNRyMQqPq4ae8sM-phsixlDduHZwHyEe9i-MPy50JkkrANv_E9kM9AvUiZRNRXZNPI0wx5g0-fwNeadiON2OQBdumXeeXxV1EE0_w6_8/s640/IMG_5572.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8v_BilokkmdcDLKpwycCjzPalDd85SLfs8jrrNRyMQqPq4ae8sM-phsixlDduHZwHyEe9i-MPy50JkkrANv_E9kM9AvUiZRNRXZNPI0wx5g0-fwNeadiON2OQBdumXeeXxV1EE0_w6_8/s320/IMG_5572.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRAnXvccXAdMFeZR4WyNh2MI72p7DYqGOEVxd-oNWjZoFHSUm0Ra_z-7iqpMdNC9KSy_B4hxojhPyaHs00IvqKRdoutK-Jrri1A9l8NNTOp4c08j8JqDZP_YelbF6RCummVl9itje1UUg/s640/IMG_5578.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRAnXvccXAdMFeZR4WyNh2MI72p7DYqGOEVxd-oNWjZoFHSUm0Ra_z-7iqpMdNC9KSy_B4hxojhPyaHs00IvqKRdoutK-Jrri1A9l8NNTOp4c08j8JqDZP_YelbF6RCummVl9itje1UUg/s320/IMG_5578.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxKJNN_Sodz2HI-vxKiQlXqCZ1Wm8fOlOfuOWJZjQz7wY8zyce332EKPhe6Rg3nC25wCGyxYnmAIgV4SwGLFauwv7KvKOmNdpm75BiXIxdB7wk9VO5gNDn9KHuYEQkTCqArrR55xtRYQM/s640/IMG_5579.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxKJNN_Sodz2HI-vxKiQlXqCZ1Wm8fOlOfuOWJZjQz7wY8zyce332EKPhe6Rg3nC25wCGyxYnmAIgV4SwGLFauwv7KvKOmNdpm75BiXIxdB7wk9VO5gNDn9KHuYEQkTCqArrR55xtRYQM/s320/IMG_5579.jpg" width="320" /></a></div><br /><div>I measured how much 4" flex pipe I needed. After coming up short,
it seems a 1.5 multiplier for how much you need is a good rule. Since
the flex pipe is exactly 4" it won't fit over the 4" PVC. I cut 4"
lengths of PVC and split them along the length removing 5/8". This
proved an effective adapter. I used duct tape to increase the tension
fit as needed. I used a hobby knife to cut through the vinyl of the flex pipe, make sure my start and end of the cut ended on one of the wire supports. I then used a wire cutter to cut through the wire.<br /></div><div><br /></div><div>I ended up using
4" to 2.25" reducers from harbor freight. They don't taper which is
preferred, but the price is right. I had considered making <a href="https://www.youtube.com/watch?v=cjLQo3GuvDo " target="_blank">homemade PVC tapers</a>, but didn't need to.<br /></div><div><br /></div><div>I
got 2.5" flex pipe, not realizing the mismatch in size. I used EVA foam
to fill the gaps from the 2.25" reducer to the 2.5" flex pipe and from
the flex pipe to equipment. I used contact cement to glue the ends of
EVA foam together.<br /></div><div><br /></div><div>While I want my flex
pipe runs as short as possible, I need some slack to disconnect
equipment. Duct tape at one end of the flex pipe to compress the pipe is
the solution to reduce slack.<br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_76m-QBpe7zEgdmR1HKmaaEDQ8HwzKYF9dtncQTDqzfmcB5m_6wJjj4Q3CuN4FKrxb3ZmZNA8HBmlTHt81yESMskvrneIFU__F83fiHGDcGUwR5hxeIE1VTVgQ-l9BvJUEzyEk9Djhtg/s640/IMG_5613.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_76m-QBpe7zEgdmR1HKmaaEDQ8HwzKYF9dtncQTDqzfmcB5m_6wJjj4Q3CuN4FKrxb3ZmZNA8HBmlTHt81yESMskvrneIFU__F83fiHGDcGUwR5hxeIE1VTVgQ-l9BvJUEzyEk9Djhtg/s320/IMG_5613.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpQ5t0ml1gLlyY4PvxHpY5UgKE4HLj6U_XglQxVSHmnvTSrlb-av0gv8A_E5LnLn9u1qBAlCH6Ioum870noi3agKKt3LnoiE2uybuDkLbdO3FECq35TNeoEJEskflIMDktXqO_XMLfPHo/s640/IMG_5614.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpQ5t0ml1gLlyY4PvxHpY5UgKE4HLj6U_XglQxVSHmnvTSrlb-av0gv8A_E5LnLn9u1qBAlCH6Ioum870noi3agKKt3LnoiE2uybuDkLbdO3FECq35TNeoEJEskflIMDktXqO_XMLfPHo/s320/IMG_5614.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMVzbUB8r_VgoYM5nFzRBVcALLnzghYrxEzmF1XCpuAPAaznrR5RjMSQjKMqnM2z-e2oZR6Qza_0aVHdle-VIzAI6bWOokhIwwSeqjb1PpgOk5hgS6LZIDZSiGgak1kWhKQA6Tu7TrNMc/s640/IMG_5615.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMVzbUB8r_VgoYM5nFzRBVcALLnzghYrxEzmF1XCpuAPAaznrR5RjMSQjKMqnM2z-e2oZR6Qza_0aVHdle-VIzAI6bWOokhIwwSeqjb1PpgOk5hgS6LZIDZSiGgak1kWhKQA6Tu7TrNMc/s320/IMG_5615.jpg" width="320" /></a></div></div><div></div><div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTSoP3f2UGJn04ds_VBZWfIGtqXO-PKkJoTMsMrG-lAP9gNW6ZV2tGzhRm1DGHCbz85_c6NKcrKFyAgQm6Fb1o0Yjiupy7hCxc61lyyLsgi9wXGqFEGEiKLoNES63Y1DLBA5YQLodP5c8/s640/IMG_5568.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTSoP3f2UGJn04ds_VBZWfIGtqXO-PKkJoTMsMrG-lAP9gNW6ZV2tGzhRm1DGHCbz85_c6NKcrKFyAgQm6Fb1o0Yjiupy7hCxc61lyyLsgi9wXGqFEGEiKLoNES63Y1DLBA5YQLodP5c8/s320/IMG_5568.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfSnc-P8tYJ5M5XWC7iLwkp6SzJ_03EgtFjr9XzRdLj17BnolkFuv6nn_7SsrorTL5BLYNjPFHosu85yeC1KcLsej7PWvS_j4SzvBCiPWVuMeCyVCdOSfx2CN5QIc6T_pKY8g2VUOEEAY/s640/IMG_5569.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfSnc-P8tYJ5M5XWC7iLwkp6SzJ_03EgtFjr9XzRdLj17BnolkFuv6nn_7SsrorTL5BLYNjPFHosu85yeC1KcLsej7PWvS_j4SzvBCiPWVuMeCyVCdOSfx2CN5QIc6T_pKY8g2VUOEEAY/s320/IMG_5569.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQPTNAAE_-D7Z7aN1xx5hddJNrlWWZ3imE8VFNiqlUcVzVJ9DFE3sDWK9D8I5yO2XaK1F1t9T0IQEVCtuQ2_GxOc4uzFZGE4hASLFaeShSMDyx-ua5ZFvmTIKX2iAuzJmFNmot5MPbY_w/s640/IMG_5570.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQPTNAAE_-D7Z7aN1xx5hddJNrlWWZ3imE8VFNiqlUcVzVJ9DFE3sDWK9D8I5yO2XaK1F1t9T0IQEVCtuQ2_GxOc4uzFZGE4hASLFaeShSMDyx-ua5ZFvmTIKX2iAuzJmFNmot5MPbY_w/s320/IMG_5570.jpg" width="320" /></a></div> </div><div>At the belt sander I used a 45* elbow that directs right at the top. An adapter didn't seem necessary.</div><div><br /></div><div>I also will have an open flex pipe to the work bench. I plan to connect a PVC flange to the end, but not sure it's necessary though it would provide an object to clamp.</div><div> </div><div>I did a few tests to see how much splitting the pick up at the table saw and band saw would affect suction. Suction is better with only one pickup, but ultimately I decided to employ two pickups. Even with a split suction from both pipes wasn't cut in half. Also two pickups is the best way to reduce sawdust.<br /></div><div><br /></div><div><div><span style="font-family: arial;"><b>
Conclusion</b></span></div>The system provides great suction. The first piece of equipment I connected was the belt sander. I sanded foam as a test and it got everything.</div><div>The next tool was a scroll saw. I wasn't able to box out the scroll saw well, but suction was still impressive, eliminating some of the sawdust covering the top. If I could box it out it would perform even better.<br /></div><div><br /></div><div>I had planned for double pickups at a few tools. I was unable to do this at the router due to space, but I don't think just one pick up will suffice since it's difficult to get a port right at the sawdust producing portion of tools.</div><div><br /></div><div>The dust collector is loud, though I already wear ear protection when using any tools with a motor. It's also one extra step before I cut anything. I have to switch it on and make sure the correct gates are open.<br /></div><p><b><span style="font-family: arial;">References</span><br /></b>I didn't incorporate all of these ideas or suggestions, but they were all part of the research process.<br />
<a href="http://benchblog.com/2015/05/dust-collector-project-part-1/" target="_blank">Dust collection project</a><br /><a href="https://www.wwgoa.com/article/simple-approach-for-dust-collection-ducting" target="_blank">Dust collection system tips</a><br /><a href="http://lumberjocks.com/ScottStewart/blog/32193" target="_blank">Dust collection system</a><br /><a href="https://www.woodmagazine.com/woodworking-tips/techniques/dust-collection/top-dust-collection-tips " target="_blank">Dust collection tips, tricks, accessories - drill press clamp</a><br /><a href="https://www.instructables.com/id/Router-Table-Dust-Collection/ " target="_blank">Router table dust collection - two pickups</a><a href=" http://www.jpthien.com/cy.htm" target="_blank"><br /></a><a href="https://wynnenv.com/products-page/woodworking-filter-pricing/35b222nano-cartridge-kit/" target="_blank">Wynn filter 35B222NANO</a><br /><a href="https://wynnenv.com/wp-content/uploads/35A-Filter-Instructions.pdf" target="_blank">Wynn filter instructions</a><a href=" http://www.jpthien.com/cy.htm" target="_blank"><br />Thien baffle plans</a><br /><a href="http://www.jpthien.com/smf/index.php?topic=137.0" target="_blank">Thien baffle sizing</a><br /><a href="https://www.popularwoodworking.com/projects/make-your-own-blast-gates" target="_blank">Make blast gates</a><br /><a href="http://benchblog.com/how-tos/how-to-make-brackets-to-hang-pvc-pipe-for-woodworking-shop-dust-collection-system/" target="_blank">Make pipe brackets </a><br /><a href="https://www.reddit.com/r/harborfreight/comments/9u053c/love_my_new_hf_2hp_dust_collector_with_added/" target="_blank">HF DC with Cyclone</a><a href="http://www.jpthien.com/smf/index.php?topic=137.0" target="_blank"><br /></a><a href="https://www.instructables.com/id/Mini-Cyclone-Bucket-Dust-Collector/" target="_blank">Make a mini-cyclone<br /></a><a href="https://www.homedepot.com/p/WEN-3-Speed-Remote-Controlled-Industrial-Strength-Air-Filtration-System-556-702-1044-CFM-3417/307410376" target="_blank">Make a cyclone<br />WEN air cleaner ($238)</a> in conjunction with DC<br /><a href="https://www.thegeekpub.com/3621/grounding-a-dust-collection-system/" target="_blank">Grounding</a><br /><a href="https://www.youtube.com/watch?v=D1JWH425o7c" target="_blank">Automated dust collection</a><a href="https://www.reddit.com/r/harborfreight/comments/9u053c/love_my_new_hf_2hp_dust_collector_with_added/" target="_blank"><br /></a><span></span></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-5610600485261056802021-04-23T02:00:00.121-04:002021-04-23T02:00:00.194-04:00Making Blast Gates for Dust Collection System<span style="font-family: arial;"><span face=""arial" , "helvetica" , sans-serif"><b>Making Blast Gates</b></span></span><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieQDR_mPvf4LgMC1O6K9wyihN2dqx7b2jmrRP47pwr3-fYKd5wo95GRSj3dPLPewGutS075AvLlKxFC3poX9MONJLXRsmO6nK0z_h4bzn0i0KU_X-LQd_GFPtIgeeIujDXVi988dPeWnQ/s640/IMG_5373.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieQDR_mPvf4LgMC1O6K9wyihN2dqx7b2jmrRP47pwr3-fYKd5wo95GRSj3dPLPewGutS075AvLlKxFC3poX9MONJLXRsmO6nK0z_h4bzn0i0KU_X-LQd_GFPtIgeeIujDXVi988dPeWnQ/s16000/IMG_5373.jpg" /></a><br />
You can get cheap blast gates, but they're not great. Nicer ones are more expensive, but you can build your own that work well and don't break the bank.<br />
<a name='more'></a><p> <br />Blast
gates restrict air flow to one tool, otherwise you wouldn't get enough
suction in a dust collection setup. Gates are made from 1/2" and 1/4" MDF as it's cheap and smooth. I need
11 for my set up.<br />
While I could get rather simple ones for a few bucks, I don't want a gate with a track that will eventually fill with sawdust and impede operation. The nicer gates are $12 each so I'm going to make my own. <br />
<br />
<b>Purchase List:</b><br />
</p><ul>
<li>(1) 4"x10' PVC pipe (or 4" coupler)<br /></li>
<li><a href="https://www.homedepot.com/p/1-2-in-x-2-ft-x-4ft-Medium-Density-Fiberboard-1508108/202089097">1/2" MDF</a> 2'x4' for the Gate Body and handles<br /></li>
<li><a href="https://www.homedepot.com/s/1%252F4%2522%2520mdf?NCNI-5">1/4" MDF</a> 2'x4' for blade and spacers/sides</li><li>1/2" wood screws <br /></li>
</ul>
<div>
<b>Subtotal: $35</b></div>
<div>
<br /></div>
<div>
<b>Tool List:</b></div>
<div>
table saw with crosscut sled<br />
round file<br />
router</div><div>1" forstner bit & 1/8" bit/drill <br /></div>
<div>
<br /></div>
<div>
<b>Cut List (each):</b></div>
<ul>
<li>(2) 6.75"x6" 1/2" MDF Gate Body - 4 3/16" hole for the pvc pipe or 4.5" hole for coupler</li>
<li>(2) 6"x0.5" 1/4" MDF spacers/sides</li>
<li>4' PVC pipe cut to 4" or coupler cut in half</li>
<li>(1) 5.75"x11.75" 1/4" MDF blade</li>
<li>(2) 5.75"x1" MDF for blade handle on each end</li>
</ul><p><a href="http://benchblog.com/how-tos/how-to-make-blast-gates-for-your-woodworking-shop-dust-collection-system/" target="_blank">How to make blast gates reference</a><br /><br />
<span face=""arial" , "helvetica" , sans-serif"><b>Blast Gates</b></span><br />Initially I planned to cut couplers
in half for each side of the gate, but that would just add an extra
joint between the wye and the gate since I will install the gate right off the wye. Using 4" PVC removes the coupler
joint. also, the other side of the gate will connect to the 4" flex hose or a 4" to 2.25" adapter.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRvw3euyunM8nK08_Yzakp2OeBlm1xg_ubGeUdyCTWZTefa2z0hh1EHemtp67s7NF0jXtb55oHlwFV120CV6hnVV8wr8TBg18Do5FpDjyq43RvIQqufLtVY2cuCjMd5SDRkAjmygyhI1w/s640/IMG_5209.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRvw3euyunM8nK08_Yzakp2OeBlm1xg_ubGeUdyCTWZTefa2z0hh1EHemtp67s7NF0jXtb55oHlwFV120CV6hnVV8wr8TBg18Do5FpDjyq43RvIQqufLtVY2cuCjMd5SDRkAjmygyhI1w/s16000/IMG_5209.jpg" /></a><br /> <br />
The blade has a hole cut into it, which does make it longer, but it removes a track that could fill with sawdust. It's frequently called a self-cleaning gate. With a track, it will eventually fill with sawdust and won't completely shut, reducing air flow. My gates don't have a track, but I do need space on each side of the gate for open and closed orientation.<br />
<br />
I created a <a href="https://withwardworks.blogspot.com/2019/03/router-circle-cutting-jig.html" target="_blank">circle cutting jig</a> for the holes.</p><p>Half of my gates had too much resistance to slide smoothly after glue up of the body. I sanded them lightly with a sander until the fit was better. It won't take much sanding, only a couple of passes.<br /></p><p></p><p>I glued the handle on one side of the gate, but screwed it on the other side in case I ever need to remove the gate or if the fit becomes an issue and I need to sand it down, I have that option.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLSBJHin9kk6CbzQ7Kg1l9bXE28U4V-l8_w9rglJl3b9qYMVEiZUesHAREhhvAK1HfpQnzNtSrWA8vaQeZkfQ_O_Endtg16IrhAco3GYrIE0smvm8ZjjfNlbcSG4kdiH-qm0xsbTzfzeg/s640/IMG_5359.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLSBJHin9kk6CbzQ7Kg1l9bXE28U4V-l8_w9rglJl3b9qYMVEiZUesHAREhhvAK1HfpQnzNtSrWA8vaQeZkfQ_O_Endtg16IrhAco3GYrIE0smvm8ZjjfNlbcSG4kdiH-qm0xsbTzfzeg/s16000/IMG_5359.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWg3uWpeS_vk1S0qqB-x1gHQ-jkMsns0quvHuLyF_AYwEaZl7S1mYfRCWkXqBEmfqpUMWkLgAakZuOZ9Y5UEv-n0OMN6ljEDdoPjUPLNNvUuS30TY6xc3HZ9jqpOv4cOD_c_CMggVgJLg/s640/IMG_5360.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWg3uWpeS_vk1S0qqB-x1gHQ-jkMsns0quvHuLyF_AYwEaZl7S1mYfRCWkXqBEmfqpUMWkLgAakZuOZ9Y5UEv-n0OMN6ljEDdoPjUPLNNvUuS30TY6xc3HZ9jqpOv4cOD_c_CMggVgJLg/s16000/IMG_5360.jpg" /></a></div><p>The body of the gate is 1/2" MDF with (2) 1/4" MDF spacers on two sides. The blades
are 1/4" with 1/2" MDF handle glued on one side and 1/2" MDF handle screwed on the
other side. I used a round file to smooth out any rough cuts from the
circle jig.</p><p>I oriented the gate in the closed position before gluing the handle, and I did the same when screwing the other handle in. This ensures full close or full open when the handle is flush with the body. <br /></p><p>I cut a half circle out of the handles with a
forstner bit to make pulling the blade easier. I painted just the body
of the gates and the handles. I was concerned that painting the blades
could cause them to swell slightly and I didn't want to have to resand
them. I also like the contrast between the white body and brown gate.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1Cr9f5J5wt47hyphenhyphentwvOYB-x0Edaz8EgM5BKCK9Mhag_mBx5xdd_D-Gi3RVwlli3plaVdci1N_ciMEExI8ExUMVxoHJtON0uRVWthScUarhnMBzwLVBlzX87PUMYTZRWfIHiQahv69bWao/s640/IMG_5361.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1Cr9f5J5wt47hyphenhyphentwvOYB-x0Edaz8EgM5BKCK9Mhag_mBx5xdd_D-Gi3RVwlli3plaVdci1N_ciMEExI8ExUMVxoHJtON0uRVWthScUarhnMBzwLVBlzX87PUMYTZRWfIHiQahv69bWao/s16000/IMG_5361.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Open</td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEildm-MQrRk1LaeSfQ8v9_wtHwjBBg-q5JP2HS8tNvcSKZQ4YLM-5DumAl3_nIsDYhllTh3LbiQZg79mCEgOxo2R6aHRTMCzfDILFC5OE4XnS9qq0bUZCP3DCYU3yEiu3s3v6bqJAZ_gOg/s640/IMG_5362.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEildm-MQrRk1LaeSfQ8v9_wtHwjBBg-q5JP2HS8tNvcSKZQ4YLM-5DumAl3_nIsDYhllTh3LbiQZg79mCEgOxo2R6aHRTMCzfDILFC5OE4XnS9qq0bUZCP3DCYU3yEiu3s3v6bqJAZ_gOg/s16000/IMG_5362.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Closed</td></tr></tbody></table><p>I cut 2.5" long PVC pipe to caulk into each side of the
gate. I caulked the opening before inserting the PVC and the joint after
the PVC pipe was in place. Have the gate closed while doing this so you
don't encroach upon the blade path. After inserting the PVC pipe, ensure the blade operates and wipe away any excess caulk.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPSbXXTJCJoMHf2ghtnl5VZv1BYFZeuQRHPWcjo-X0qBrbWUDXf7d_FK_d_w49Sa7IGeVfK5B-OdQadUyyY_t23ZJpcdWCWagQ2dFo32F4e0jLNPO8ACI41lKkmpm1GfoAPN44gk-sdzg/s640/IMG_5372.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPSbXXTJCJoMHf2ghtnl5VZv1BYFZeuQRHPWcjo-X0qBrbWUDXf7d_FK_d_w49Sa7IGeVfK5B-OdQadUyyY_t23ZJpcdWCWagQ2dFo32F4e0jLNPO8ACI41lKkmpm1GfoAPN44gk-sdzg/s16000/IMG_5372.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieQDR_mPvf4LgMC1O6K9wyihN2dqx7b2jmrRP47pwr3-fYKd5wo95GRSj3dPLPewGutS075AvLlKxFC3poX9MONJLXRsmO6nK0z_h4bzn0i0KU_X-LQd_GFPtIgeeIujDXVi988dPeWnQ/s640/IMG_5373.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieQDR_mPvf4LgMC1O6K9wyihN2dqx7b2jmrRP47pwr3-fYKd5wo95GRSj3dPLPewGutS075AvLlKxFC3poX9MONJLXRsmO6nK0z_h4bzn0i0KU_X-LQd_GFPtIgeeIujDXVi988dPeWnQ/s16000/IMG_5373.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgacGaXqhWv59Se_Nav5I7Gs6XG3PhvcLtq0rZiqutW8_qmSOXjZA-Oyn41oQW-JWaMGQng1U4gnKRggsHmi52Newf3n3rS-CEhhCYDn8ziHFcSe4uU_VwSCs_71YqeW9EWjHpnzyiKf_Y/s640/IMG_5374.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgacGaXqhWv59Se_Nav5I7Gs6XG3PhvcLtq0rZiqutW8_qmSOXjZA-Oyn41oQW-JWaMGQng1U4gnKRggsHmi52Newf3n3rS-CEhhCYDn8ziHFcSe4uU_VwSCs_71YqeW9EWjHpnzyiKf_Y/s16000/IMG_5374.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWAKsnJeJi4tI0D-KYNOOQwvsd_nfnAE7h4RwoZTxsF22uwmb4wolo8y3YQNsrxf6Laxhrjzg3elH37hVyLwcAnO54590k3ap6FJEM_7m_fARX8L7sFGpbxvwTm0Y2ECCXN07I-l08OBo/s640/IMG_5440.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWAKsnJeJi4tI0D-KYNOOQwvsd_nfnAE7h4RwoZTxsF22uwmb4wolo8y3YQNsrxf6Laxhrjzg3elH37hVyLwcAnO54590k3ap6FJEM_7m_fARX8L7sFGpbxvwTm0Y2ECCXN07I-l08OBo/s16000/IMG_5440.jpg" /></a></div>
The 4" flex hose will not fit over 4" PVC pipe. I added an adapter which was 4" PVC with 5/8" cut out of it. This allows the flex pipe to fit over it and it fits inside the 4" PVC out on the blast gate. I added duct tape where the tension fit was loose.<br />WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-57522761621285750622021-04-23T02:00:00.085-04:002021-04-23T02:00:00.195-04:00Building a Thien Baffle for Dust Collection & Chip Separation<span face=""arial" , "helvetica" , sans-serif"><b>Building a Thien Baffle</b></span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLZTyFh9mY6QCAUtkgXJgWMjIPA5h2hED6MHvD7F9UYzqOT6AfFDyycL3riwqyAoU8T__wILw-93HTRiobITa1fr-gT_RdMTdRaB4qL9rhnioWftcsJyTprgvK6315ZGm_kPdI1v1RvqY/s1600/IMG_1745.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLZTyFh9mY6QCAUtkgXJgWMjIPA5h2hED6MHvD7F9UYzqOT6AfFDyycL3riwqyAoU8T__wILw-93HTRiobITa1fr-gT_RdMTdRaB4qL9rhnioWftcsJyTprgvK6315ZGm_kPdI1v1RvqY/s640/IMG_1745.jpg" width="640" /></a></div>
<br />
A Thien baffle separates chips, preventing them from hitting the dust collection impeller and also collects a lot of dust, keeping your filter clean and maintaining air flow.<br />
<a name='more'></a><p></p><p><br />
I researched both a <a href=" http://www.jpthien.com/cy.htm" target="_blank">Thien baffle</a> and a <a href="https://www.homedepot.com/p/WEN-3-Speed-Remote-Controlled-Industrial-Strength-Air-Filtration-System-556-702-1044-CFM-3417/307410376" target="_blank">cyclone</a> before deciding on the Thien. </p><p>I started with a basic plan in Sketchup. I knew the size of the trash can I was using. I wanted to match that width as close as I could since this is going in a corner.<br />
The interior of the baffle has a slot for sawdust to drop into the trash can, while the impeller is mounted on top of the baffle to reduce bends in the line.<br />
<br />
<b>Purchase List:</b><br />
</p><div>
(1) 4'x8' sheet of plywood<br />
(4) 6" lengths of 5/16" threaded rod<br />
(16) 5/16" fender washers<br />
(16) 5/16" nuts<br />
6"x38" vinyl, plastic or other flexible panel. I used an <a href="https://www.homedepot.com/p/Home-Decorators-Collection-Stony-Oak-Grey-6-in-x-36-in-Luxury-Vinyl-Plank-20-34-sq-ft-case-60198/207047495">LVT tile</a><br />
(1) trash can<br />
caulk to seal joints, gaps, etc.<br />
<u>Total Cost: $120</u></div>
<div>
<br /></div>
<div>
<b>Tool List:</b></div>
<ul>
<li>table saw</li>
<li>router</li>
<li>jig saw/band saw</li>
<li>drill </li>
<li>5/16" drill bit</li>
<li>1/4" router cutting bit</li>
<li>1/8" router cutting bit</li>
<li>router cutting jig (<a href="https://withwardworks.blogspot.com/2019/03/router-circle-cutting-jig.html">my how to</a>)</li>
</ul>
<div>
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<b>Cut List:</b></div>
(2) 18"x19" blanks for the top and bottom<br />
(1) 4.75"x2"<br />
(1) 4.75"x5.75"<br />
(1) 4.75"x9.25"<br />
(1) 37" long x 6" hardboard panel for the sides<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />
With adding dust collection, I wanted to maximize efficiency. The <a href="http://www.jpthien.com/cy.htm">Thien Baffle</a> protects the impeller from being hit by wood chips and also collects a lot of dust, keeping the filter clean. The cleaner the filter, the better the air flow.<br />
<br />
I considered making a cyclone style filter but I couldn't find anything confirming the effectiveness.<br />
The Thien baffle's use is widespread, and it also allows the trash can to get rather full before pulling the excess into the filter.<br />
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I created a few iterations in Sketchup before finalizing a design.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Procedure</b></span><br />
I started with a galvanized trash can, this dictates the size of the baffle. This trash can has a 17" inner clear diameter. I chose this trash can as I'm putting my dust collection in a corner, and I have to maintain a certain width.<br />
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While you can buy trash can tops that mimic the design and some designs have the baffle completely inside the trash can, I wanted the PVC pipe to run straight into the baffle with no 90* turns.<br />
<br />
The baffle will sit on top of the trash can with a plywood lip to ensure good fitment.<br />
<br />
I rough cut 18"x19" blanks for the top and bottom of the baffle. Both have a 2"x5.75"x10" extension for the pipe inlet. I made the rough cuts a bit wider than necessary to leave room for the router to trim.<br />
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The top has a 5" hole for the dust collector motor. The motor will feed directly into the filter bag.<br />
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The interior bottom of the baffle has a 240* 1.5" wide slot. Both top and bottom have a 1/8" wide x 1/4" channel for the rubber sides.<br />
That channel runs right into the bottom slot. You don't want a ledge for dust to sit/collect.<br />
<br />
The circle cutting jig (<a href="https://withwardworks.blogspot.com/2019/03/router-circle-cutting-jig.html">check out the how to</a>) made cutting the curves very easy while ensuring the top and bottom were exactly the same size.<br />
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I cut each slot with two passes as trying to cut through .75" in one pass was too much strain on the router. The jig ensures each pass is aligned. <br />
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A 4.25" diameter hole was cut out of the 4.75"x5.75" cut. This is for the inlet.<br />
<br />
While
I used (4) threaded rods to space the top and bottom, doing this again I
might have just used wood posts around the perimeter.<br />
I was reusing rods, so I had to re-thread them to clean them.<br />
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The top and
bottom are sandwiched with washers and nuts.<br />
I sketched up a few iterations and while the first few didn't have space around the perimeter, the final version did as I needed a ledge for the baffle to sit on a trash can. <br />The LVT floor plank sides are 6" deep along the slot, but 5.25" everywhere else. A
quarter of an inch is inside the channel on the top and bottom plate. I
didn't want to create any kind of ledge to catch dust so the sides
extend the depth of the slot. Originally I was going to use hardboard,
but it just doesn't flex enough to fit the diameter. It snapped trying
to fit it to a 17" diameter.
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A ring with a 17" outer
diameter was glued to the bottom. It's 1" wide and the face is flush
with the slot. This ring helps mount the baffle to the trash can.<br />
<br />
I
glued the inlet together and to the bottom first. I glued it to the top
at the same time I caulked the channels for the side and tightened the
nuts down for a tight fit.<br />
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I measured the nut/washer height to
exactly 4.75". I tightened the bottom nuts down and then prepped to
caulk the sidewall in place on the top and bottom. I wanted to be sure
it was air tight. With the sides being in a channel, caulk fills any potential air gaps.<br />
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I added weather stripping to the trash can. I want a air tight fit between the baffle and can.<br />
<br />
I added a tab on one of the back corners to prevent the baffle from wanting to turn. The bottom plate needed to be about an inch wider to sit on the trash can properly.<br />
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I considered attaching springs from my scrap to hold the baffle to
the trash can, hooking to the can's handles and drilling a hole into the
bottom plate. With the motor mounted to the wall and the way my trash can is mounted, I didn't need the springs. The trash can sits on a plywood sheet bolted to a scissor jack. The scissor jack lifts the trash can tight against the baffle which is hung from the motor. The motor is mounted to the wall. Lowering the scissor jack lowers the trash can and allows for removal.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Conclusion<br /></b></span>A
chip separator of any sort is mandatory for a dust collection system.
It protects your impeller and filter. While there are certainly
expensive out of the box separators, this is much more affordable and a
quick project. Plus I like making stuff.<br />
I painted the outside white to match the PVC pipe and the walls.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0-HHiPTwCBVuLs4Ue-ziYrUZFArP-G2v6c9bPu7ZhLYLItg6liBDWhbrcNH6wBdCKxkaaZPgvEESxHy_Ye_Ldb2Yph1LTltYrRieac7pt4Vm_-lueOqCll9pf8GSr_g0PQqyogaAHZzQ/s1600/IMG_1749.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0-HHiPTwCBVuLs4Ue-ziYrUZFArP-G2v6c9bPu7ZhLYLItg6liBDWhbrcNH6wBdCKxkaaZPgvEESxHy_Ye_Ldb2Yph1LTltYrRieac7pt4Vm_-lueOqCll9pf8GSr_g0PQqyogaAHZzQ/s400/IMG_1749.jpg" width="400" /></a></div>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-75353664766808465652021-02-12T02:00:00.002-05:002021-03-06T09:07:23.073-05:00ABS Plastic Car Panel<span face=""arial" , "helvetica" , sans-serif"><b>Interior Cover Panel</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj36yyuk-1E8M65Tq85TWSbEtZWDc2UlRHxCWDJu4A3S8mbdsldjztnqhFPCedBCliE3HEnruUua-iUbSrdZqR3p7-xZTNdUCo61wRRMRSSoLpt_gdKPpulm_2QCYST5sC1-14lE3tNcE/s640/IMG_4344+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhj36yyuk-1E8M65Tq85TWSbEtZWDc2UlRHxCWDJu4A3S8mbdsldjztnqhFPCedBCliE3HEnruUua-iUbSrdZqR3p7-xZTNdUCo61wRRMRSSoLpt_gdKPpulm_2QCYST5sC1-14lE3tNcE/s16000/IMG_4344+copy.jpg" /></a><br />The task was to create an ABS cover panel.<br />
<a name='more'></a>I started with a basic plan <br />
<br />
<b>Purchase List:</b><br /><a href="https://amzn.to/2PG1qTW" target="_blank">ABS black textured plastic</a> (paid link)<br /><div>
<b>Subtotal: $20</b></div>
<div>
<br /></div>
<div>
<b>Tool List:</b></div>
<div>scissors, tape, pen</div><div><a href="https://amzn.to/3qmKluL" target="_blank">3M 77 spray adhesive</a> (paid link)<br /></div><div>band saw<br />heat gun</div><div>sanding block<br /></div><p><span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />The panel went into a 1932 Ford pickup project. An AC system was retrofitted into the cab, and this panel will protect the hoses entering the cab at the passenger floor board.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Cardboard Templating</b></span><br />
I started with understanding what the panel needed to do, how it would attach, and what it needed to protect. From there, I proceeded with pieces of cardboard, cutting, fitting, and recutting to get a basic shape. I taped additional pieces of cardboard together as needed, and once the shape was complete I used tape to refine edges.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0IdpcrtEFAHWAWht3GIc_SLGW2oOP50OeL156MV7SnfaZBJJP2ruKlfjpKVhaajyUczNuxpcE9zHoZGlMQqSNsZAhS2NAehXdjxdJlP3jFYMw51Vr3RZ3EvN0Mvn6AVUrgl5rCmOFM1g/s640/IMG_4289+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0IdpcrtEFAHWAWht3GIc_SLGW2oOP50OeL156MV7SnfaZBJJP2ruKlfjpKVhaajyUczNuxpcE9zHoZGlMQqSNsZAhS2NAehXdjxdJlP3jFYMw51Vr3RZ3EvN0Mvn6AVUrgl5rCmOFM1g/s16000/IMG_4289+copy.jpg" /></a></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjg9qQjkxAZe9qrS3y_ZHhyleKKNCep9tUomilv-LGj6thbYmqn4K-rlajSzaGa7IIdfuzyCW19FDAkG85G-1rxv0hujzE9BXfZEh4EGjqjIJHqBXvnaczjCBDLrPNoke9My9B8c8_vFrY/s640/IMG_4290+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjg9qQjkxAZe9qrS3y_ZHhyleKKNCep9tUomilv-LGj6thbYmqn4K-rlajSzaGa7IIdfuzyCW19FDAkG85G-1rxv0hujzE9BXfZEh4EGjqjIJHqBXvnaczjCBDLrPNoke9My9B8c8_vFrY/s16000/IMG_4290+copy.jpg" /></a></div><p><span face=""arial" , "helvetica" , sans-serif"><b>Creating a Plastic Shape</b></span><br />
I used the cardboard template to trace an outline onto paper. I wanted the plastic shape to be a single piece. I drew an outline and also noted where I would fold the plastic. I left tabs to attach the side that folds in so I could plastic weld it later.<br /></p><p>I sprayed just the paper, make sure it's the back side, with spray adhesive. I attached that to the ABS plastic, only spraying the paper makes removal easier.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8sllD6woEJRwXI2IppEDnYj0E_vaasrJrY9qXtxMwxksjU__5zboOvRw2KGTorNc2XAO332zZBx8MZxswWcKRAHX1fCue83sAGMQVI_jKhGTeoJ5rsETTczjFLTIFaDJZ-nVRDm1PL9s/s640/IMG_4291+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8sllD6woEJRwXI2IppEDnYj0E_vaasrJrY9qXtxMwxksjU__5zboOvRw2KGTorNc2XAO332zZBx8MZxswWcKRAHX1fCue83sAGMQVI_jKhGTeoJ5rsETTczjFLTIFaDJZ-nVRDm1PL9s/s16000/IMG_4291+copy.jpg" /></a></p><p>A band saw cut the plastic to shape. I used a sanding block to smooth edges and any burrs. I used a heat gun to shape the plastic, leaving the paper in place as it had folding notes. The plastic can get very hot. To create some of the bends, I had to heat, bend, and repeat many times. You may get a few bows in the plastic, but careful heating can help keep the panel faces straight. While heating and shaping, use a workbench to help fold. Take bends slowly, this will help prevent warping faces.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4NA3yPVEWhkmK0vsSdEvurtyUG5J6QFAVop1iYsygL1BEm0MYMooo2RtuQ3l9xHdku2HE__r4JspT_gTebNAjNKl8A1vI6k3WUJzPRo-Itj5TMXk2p_8E4jReOnbWScVvgfPJUV57xqU/s640/IMG_4292+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4NA3yPVEWhkmK0vsSdEvurtyUG5J6QFAVop1iYsygL1BEm0MYMooo2RtuQ3l9xHdku2HE__r4JspT_gTebNAjNKl8A1vI6k3WUJzPRo-Itj5TMXk2p_8E4jReOnbWScVvgfPJUV57xqU/s16000/IMG_4292+copy.jpg" /></a></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0PrSCpycdfORgn9MmrLiA4M4sbe9zzvTbTnvqVzz_qdlqWcJROlev-XI7YMih0pgwTHeqMqwtSbNXXJ2guN6M5VyRFXmMbo_OH6qY5Ah84bLWwgjY0Yhvu3asCyAmnNkzUNaByxWpeME/s640/IMG_4293+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0PrSCpycdfORgn9MmrLiA4M4sbe9zzvTbTnvqVzz_qdlqWcJROlev-XI7YMih0pgwTHeqMqwtSbNXXJ2guN6M5VyRFXmMbo_OH6qY5Ah84bLWwgjY0Yhvu3asCyAmnNkzUNaByxWpeME/s16000/IMG_4293+copy.jpg" /></a></div>It's important to make sure you glue the 'correct' side. I didn't and realized I had shaped the panel with the smooth side out. I tested the backwards panel in the truck and noted a few adjustments.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT3NAzPWqaAJgUQ1zJZqt5Uz-fHirT9Lyw-uQZMCNaZj97dVmQyC9CpZ43CeAzm-44viMMQZccf5wydxW_kHYrdw1bMUBaI7aq_zuX67LzKLGgv1ivTbxNSrLLhpak7wY2WKBLmwYcDxo/s640/IMG_4343+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT3NAzPWqaAJgUQ1zJZqt5Uz-fHirT9Lyw-uQZMCNaZj97dVmQyC9CpZ43CeAzm-44viMMQZccf5wydxW_kHYrdw1bMUBaI7aq_zuX67LzKLGgv1ivTbxNSrLLhpak7wY2WKBLmwYcDxo/s16000/IMG_4343+copy.jpg" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI4ET_GGPDv5KvjUplPbdDZMiEpSgSu-WCYw7kVPODX4sLrvN3t7HtJyVJgR7rcm1YMppo36XnBLXLARQgDOvqLiADY1OHvq0UnoYE4Q2rJlNaYvff0i5pQW2DJI_gesRA1RaNGlNHq3M/s640/IMG_4345+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI4ET_GGPDv5KvjUplPbdDZMiEpSgSu-WCYw7kVPODX4sLrvN3t7HtJyVJgR7rcm1YMppo36XnBLXLARQgDOvqLiADY1OHvq0UnoYE4Q2rJlNaYvff0i5pQW2DJI_gesRA1RaNGlNHq3M/s16000/IMG_4345+copy.jpg" /></a></div><span face=""arial" , "helvetica" , sans-serif"><b>Final Thoughts</b></span><span face=""arial" , "helvetica" , sans-serif"><b></b></span><br />Being at the floor level, it provides leeway if the panel isn't quite perfect. The panel blends with the interior so that you almost don't notice it. It's main job is to protect the AC hoses and it does that.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmGjq-oL8h226aWla-WjCZuK7tZAuFcmM2VmkNvJ0LRW-s4ARfFFSTYMAS2ugPXE2cS3yD2KbmtRA93WqSqy2EjLTdvnSPCI553SbnWaBV3B2ki97Ck1tZbbNnzC3WB5GVI8aWxiw3ESM/s640/IMG_4374+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmGjq-oL8h226aWla-WjCZuK7tZAuFcmM2VmkNvJ0LRW-s4ARfFFSTYMAS2ugPXE2cS3yD2KbmtRA93WqSqy2EjLTdvnSPCI553SbnWaBV3B2ki97Ck1tZbbNnzC3WB5GVI8aWxiw3ESM/s16000/IMG_4374+copy.jpg" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiducfsPAoRnitwEhGpHUhldwjH0CKbH4ubJwkKfIjL5h4X3_Z7nhC6EY6tZDafMVj_60Pk_G933sMREyhQozeVyEskjsNRkDMLX_KtSFTlc5DtKUgauNcfWRXGbjMwg2ky6ViPk90eNMc/s640/IMG_4386+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiducfsPAoRnitwEhGpHUhldwjH0CKbH4ubJwkKfIjL5h4X3_Z7nhC6EY6tZDafMVj_60Pk_G933sMREyhQozeVyEskjsNRkDMLX_KtSFTlc5DtKUgauNcfWRXGbjMwg2ky6ViPk90eNMc/s16000/IMG_4386+copy.jpg" /></a><br /><p></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-68580373725708532232021-02-05T02:00:00.170-05:002021-03-10T09:31:13.296-05:00Table Saw Stand Improvements<span face=""arial" , "helvetica" , sans-serif"><b>Table Saw Stand Upgrades</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGecNv3tuLP565cHiXjOxZdBH3qtgLwLydhAM6m957E5be0J1SDfvTh0vnotegdN4D_fn5g2KOXsiwBQ3gOEDxn0hi9kQXDXMw-3K1NoCKv-PWpLW18lJw5ej36YlJWngMisSYy5B1Cuc/s640/IMG_4232+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGecNv3tuLP565cHiXjOxZdBH3qtgLwLydhAM6m957E5be0J1SDfvTh0vnotegdN4D_fn5g2KOXsiwBQ3gOEDxn0hi9kQXDXMw-3K1NoCKv-PWpLW18lJw5ej36YlJWngMisSYy5B1Cuc/s16000/IMG_4232+copy.jpg" /></a><br />I needed a few improvements to make my table saw stand more efficient.<br />
<a name='more'></a><br />I needed the top of the table saw taller to out feed to my recently completed work bench, a shelf for pencils/bench dogs, a hanger for the fence, and a better push stick.<br /><p>
<br />
<b>Purchase List: (all wood used was scrap so this was a low cost project)</b><br />6"x6"x8' pressure treated lumber - $40<br />(4) 1/2", 6" long bolts - $6<br />(8) 1/2" washers - $3<br />1/8" scrap plywood - $15/sheet<br />3/4" scrap plywood - $40/sheet<br />2" coarse thread screws - $7/box<b><br /></b>1/8" scrap and 1" deck board<b><br />Subtotal: This depends on what you have on hand, I only bought bolts and washers</b><br />
</p>
<div>
<b>Tool List:</b></div>
<div>
table saw with crosscut sled<br />
circular saw</div><div>hand saw<br />band saw</div><div>drill with 1/2" and 1/8" bits</div><div>round rasp<br /></div>
<div>
<br /></div>
<div>
<b>Cut List:</b></div>
<div>
(2) 15.5" long 6"x6" - table saw lift</div><div>(1) shelf 13"x3"<br /></div><div>(2) shelf brackets 3"x3.5"<br /></div><div>(2) fence brackets 6"x5"<br />(1) 1/8" ply push stick 11"x5"<br />(1) 1" deck board push stick 11"x5"</div><div> </div><div><span face=""arial" , "helvetica" , sans-serif"><b>Table Saw Lift</b></span><br />The
top of the table saw needed to be 5.5" taller, which is the exact
dimension of a 6x6. If I needed less height, I would have trimmed down
one face. If I needed more height I would have added 1/8", 1/4", 1/2",
or 3/4" plywood spacers as needed. I cut the 6x6's to the width of the
table saw base to 15.5". They are thicker than my table saw blade, so I cut all 4 sides on the table saw and used a hand saw to cut the center core the table saw couldn't reach.<br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBB6cp2-oajgosxCVwiEdtKv2RwxA9dD1S6F-PrPL4cKcvncq3PE66JhCVt6fjl5Gu6E_qNh24FIMYfDf5MXcdCSIO5e2fi-sc1oMVyzDsz6etjpiqv2pD8Z13-TjvdWuySh0-eezvzLo/s640/IMG_4235+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBB6cp2-oajgosxCVwiEdtKv2RwxA9dD1S6F-PrPL4cKcvncq3PE66JhCVt6fjl5Gu6E_qNh24FIMYfDf5MXcdCSIO5e2fi-sc1oMVyzDsz6etjpiqv2pD8Z13-TjvdWuySh0-eezvzLo/s320/IMG_4235+copy.jpg" width="320" /></a></div><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7J5KrYsXnUd26Vhxz_i8uOB6NckxNrPAsvaTuMdoBSrXGetzWFdPKa5juAirJRfkGgPEtSNdlgr2V-gZ0kyKJBz5gAo3y5npEtEyogYla3QS0VRbWRNhNLk9MpJh11La_ODPmcmiZDw/s640/IMG_4218+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7J5KrYsXnUd26Vhxz_i8uOB6NckxNrPAsvaTuMdoBSrXGetzWFdPKa5juAirJRfkGgPEtSNdlgr2V-gZ0kyKJBz5gAo3y5npEtEyogYla3QS0VRbWRNhNLk9MpJh11La_ODPmcmiZDw/s320/IMG_4218+copy.jpg" width="320" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7J5KrYsXnUd26Vhxz_i8uOB6NckxNrPAsvaTuMdoBSrXGetzWFdPKa5juAirJRfkGgPEtSNdlgr2V-gZ0kyKJBz5gAo3y5npEtEyogYla3QS0VRbWRNhNLk9MpJh11La_ODPmcmiZDw/s640/IMG_4218+copy.jpg" style="margin-left: 1em; margin-right: 1em;"></a><br />I marked the existing bolts holes and drilled through the 6x6. I replaced the existing bolts with 6" long bolts, adding a washer at the bolt head and nut. Since my drill bit isn't long enough to go all the way through, I carefully marked the holes on each side of the lift and drilled from both sides. Use a rasp on the holes if needed.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Pencil Shelf</b></span><br />For the pencil shelf, I wanted it to angle back to prevent pencils rolling out. I wanted a gap against the table saw so it wouldn't collect sawdust, and I decided to make it removable for easy clean up. The brackets are slotted for 1/8" plywood with a tab at the top for a screw. I pre drilled screw holes. The shelf sits in the slots, it isn't attached. I cut the brackets on a band saw.<br />
<p></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgys8KTOH9sdoGfJYPwrr0-N-or8a7rgUuZ3pc23rS71LEhPsQvJTBi1rIxT5LQjWJIr_IvPLrNFVvFuQIxGtRZt6oAxJVEG4EuDR8l27AYN9fvkMhiTZp-vlcSMX628KKlkSJzUETHSk/s640/IMG_4231+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgys8KTOH9sdoGfJYPwrr0-N-or8a7rgUuZ3pc23rS71LEhPsQvJTBi1rIxT5LQjWJIr_IvPLrNFVvFuQIxGtRZt6oAxJVEG4EuDR8l27AYN9fvkMhiTZp-vlcSMX628KKlkSJzUETHSk/s320/IMG_4231+copy.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfNig1z-3ZJQDwTLrkOWhtBWE12gFGMCrIGHwziSKKQfJ9oCctlC2sAmDesXjzD5g9LzomCa5eEZczk-BCzyJjLpw_qfNR75aXrQjxa5dt2gsZMHH5rJEFa7iHR8W0TSyEOchoAMOCGts/s640/IMG_4233+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfNig1z-3ZJQDwTLrkOWhtBWE12gFGMCrIGHwziSKKQfJ9oCctlC2sAmDesXjzD5g9LzomCa5eEZczk-BCzyJjLpw_qfNR75aXrQjxa5dt2gsZMHH5rJEFa7iHR8W0TSyEOchoAMOCGts/s320/IMG_4233+copy.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO1YvHA3PgCg_-uTwX1rf3vHb1RHmpkDzwrfvgURSy536VM2xj_1hMGiOx0Yq2wSiNHymRLuMgGxjF5um9d_Y9hKb9E7ywx3m0r8NNpZldBqXLcgSk4Vtf0Lo2X5ZLHXrR1l1uCy6BILg/s640/IMG_4234+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO1YvHA3PgCg_-uTwX1rf3vHb1RHmpkDzwrfvgURSy536VM2xj_1hMGiOx0Yq2wSiNHymRLuMgGxjF5um9d_Y9hKb9E7ywx3m0r8NNpZldBqXLcgSk4Vtf0Lo2X5ZLHXrR1l1uCy6BILg/s320/IMG_4234+copy.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBB6cp2-oajgosxCVwiEdtKv2RwxA9dD1S6F-PrPL4cKcvncq3PE66JhCVt6fjl5Gu6E_qNh24FIMYfDf5MXcdCSIO5e2fi-sc1oMVyzDsz6etjpiqv2pD8Z13-TjvdWuySh0-eezvzLo/s640/IMG_4235+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBB6cp2-oajgosxCVwiEdtKv2RwxA9dD1S6F-PrPL4cKcvncq3PE66JhCVt6fjl5Gu6E_qNh24FIMYfDf5MXcdCSIO5e2fi-sc1oMVyzDsz6etjpiqv2pD8Z13-TjvdWuySh0-eezvzLo/s320/IMG_4235+copy.jpg" width="320" /></a></div><span face=""arial" , "helvetica" , sans-serif"><b>Fence Brackets</b></span><br />
The fence brackets are wide enough for the fence with a tab at the top for a screw. I cupped the bracket so the fence couldn't slide off/out. I pre drilled screw holes.<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7J5KrYsXnUd26Vhxz_i8uOB6NckxNrPAsvaTuMdoBSrXGetzWFdPKa5juAirJRfkGgPEtSNdlgr2V-gZ0kyKJBz5gAo3y5npEtEyogYla3QS0VRbWRNhNLk9MpJh11La_ODPmcmiZDw/s640/IMG_4218+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjC7J5KrYsXnUd26Vhxz_i8uOB6NckxNrPAsvaTuMdoBSrXGetzWFdPKa5juAirJRfkGgPEtSNdlgr2V-gZ0kyKJBz5gAo3y5npEtEyogYla3QS0VRbWRNhNLk9MpJh11La_ODPmcmiZDw/w400-h300/IMG_4218+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI3R6EAtmLc66Nj4AFtek5_1ienJl8Fi06i4CDsITxl7Z8MPelqPGku2KHGOo05cJ73R16yq-2nvUKGoEjVpAkhlZ0uL9q4FcGti-mHmkH1oCLK-TAWYRICHgexPiCT-zPk9sEeFE12qM/s640/IMG_4219+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI3R6EAtmLc66Nj4AFtek5_1ienJl8Fi06i4CDsITxl7Z8MPelqPGku2KHGOo05cJ73R16yq-2nvUKGoEjVpAkhlZ0uL9q4FcGti-mHmkH1oCLK-TAWYRICHgexPiCT-zPk9sEeFE12qM/w400-h300/IMG_4219+copy.jpg" width="400" /></a></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Push Sticks</b></span><br />
I cut a proof of concept out of 1/8" ply to check the size and decided to keep that one as sacrificial. I also cut a push stick out of 1" deck board and painted it with spray paint. I opted for 1" over 3/4" due to ergonomics. The fade is done by lightly feathering the spray paint from one color to the next. Painting is an unnecessary step for a push stick that will eventually get replaced, but I like the look anyway.<br />The shape of the handle is based on a saw handle I like. The notch towards the nose is for hanging the push stick off the table saw. The hood at the back helps push wood, while the long nose exerts vertical force on the work piece.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY7ol1tLqjJCvjbPrGscm-pa3nAUU3i1PYPLysXb2NceuhzMSqoGu4lkll7Ylx39L0RbW0-nhZcLFIoqQ0eTo-VrlmeOk-Seiz9wtCsn14pHIrJX-_ypboZrd57LTzJER3k8BR8a2Y9mU/s640/IMG_4238+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY7ol1tLqjJCvjbPrGscm-pa3nAUU3i1PYPLysXb2NceuhzMSqoGu4lkll7Ylx39L0RbW0-nhZcLFIoqQ0eTo-VrlmeOk-Seiz9wtCsn14pHIrJX-_ypboZrd57LTzJER3k8BR8a2Y9mU/w400-h300/IMG_4238+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZINlNz8gsOR-olJrOaI4lKTsqh-WGJu8Q4PlkXd11jF1JbzmbTbo-MYYPWJoRRolluSRzV7PQW3viWBmm6fAvjfwQTFzbj7gnfZlBHVzTtVDu7eBIUmrnfPjWm7B6XiNPJHiH10jKRYk/s640/IMG_4239+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZINlNz8gsOR-olJrOaI4lKTsqh-WGJu8Q4PlkXd11jF1JbzmbTbo-MYYPWJoRRolluSRzV7PQW3viWBmm6fAvjfwQTFzbj7gnfZlBHVzTtVDu7eBIUmrnfPjWm7B6XiNPJHiH10jKRYk/w400-h300/IMG_4239+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLbZt-w39wJ7zLy-G_Z2nU_xr4p97D5FVRY2BV18c5uYxvBA1OyPks_uLe8UBEGH0_-EKvua24fmagvOXGF6IdnnkkI79D2Ar9pHobnIYSJIJi-WeN1eqHEWn9ziNLiAuSw5Tcoq9dCsk/s640/IMG_4240+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLbZt-w39wJ7zLy-G_Z2nU_xr4p97D5FVRY2BV18c5uYxvBA1OyPks_uLe8UBEGH0_-EKvua24fmagvOXGF6IdnnkkI79D2Ar9pHobnIYSJIJi-WeN1eqHEWn9ziNLiAuSw5Tcoq9dCsk/w400-h300/IMG_4240+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-J_Bg9XL_MBrfLLMdog4TUjgdvuMAK4pyZv1KBsFeGndxjv-x_qpvOZYncg1w2CaZV7RAQk5Y3sKjx17rcaWjGwv3yk7RWVwhyfQQqPHMOEo6LyavlBSAIbX840HPLi1jAS9Fi7jGdpw/s640/IMG_4273+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-J_Bg9XL_MBrfLLMdog4TUjgdvuMAK4pyZv1KBsFeGndxjv-x_qpvOZYncg1w2CaZV7RAQk5Y3sKjx17rcaWjGwv3yk7RWVwhyfQQqPHMOEo6LyavlBSAIbX840HPLi1jAS9Fi7jGdpw/w400-h300/IMG_4273+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKb4MuJS9PRYV50npLNleYSMYaBsbrDTCD8-CLJ0VF6wO3fl1-Dk_NNxkBZwUUC3FPRDw2t2KVqwHnQmDtpt-e20JIq8EuqYkV6x608Y2oAbFaZMNDcVTo22GDok_gSNvRwGAAVnuPmtg/s640/IMG_4274+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKb4MuJS9PRYV50npLNleYSMYaBsbrDTCD8-CLJ0VF6wO3fl1-Dk_NNxkBZwUUC3FPRDw2t2KVqwHnQmDtpt-e20JIq8EuqYkV6x608Y2oAbFaZMNDcVTo22GDok_gSNvRwGAAVnuPmtg/w400-h300/IMG_4274+copy.jpg" width="400" /></a><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHcLUbsEOdFrc4TVy-_tw1BRP0Y7JsSYQZZs-fWO6tNtVmZZwec7Rnf1MtxpMObnxHCOtqagqCxxJor3Qv-LfFWdsqjHJM3iFU7rV9fNO3_03P00ixv1QCcs5XbTQXpBHudF5eS3MMwOE/s640/IMG_4330+copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHcLUbsEOdFrc4TVy-_tw1BRP0Y7JsSYQZZs-fWO6tNtVmZZwec7Rnf1MtxpMObnxHCOtqagqCxxJor3Qv-LfFWdsqjHJM3iFU7rV9fNO3_03P00ixv1QCcs5XbTQXpBHudF5eS3MMwOE/w400-h300/IMG_4330+copy.jpg" width="400" /></a></div><br /></div><p></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-31306049965888395892021-01-15T02:00:00.188-05:002021-03-08T15:37:43.930-05:00Shadow Box Build<span face=""arial" , "helvetica" , sans-serif"><b>Shadow Box</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI_79gzp4w-763fYmRU0tFps8viBD_hR38IKhqCDk5v_dzluDY3XXq9wYZHso5RbuvQG_6WwjyJ5plciRl-_IaeFGrTms_rYgvvL7yC_tfhygxaTdmsOhCldK4qsh4LLy7qIVZQxy3x7g/s640/IMG_4339+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI_79gzp4w-763fYmRU0tFps8viBD_hR38IKhqCDk5v_dzluDY3XXq9wYZHso5RbuvQG_6WwjyJ5plciRl-_IaeFGrTms_rYgvvL7yC_tfhygxaTdmsOhCldK4qsh4LLy7qIVZQxy3x7g/s16000/IMG_4339+copy.jpg" /></a><br />I like the idea of these, I just needed an idea. With the holiday season, inspiration struck<br />
<a name='more'></a>I made it Christmas themed, though for my personal use I'd want something darker, post apocalyptic.<br />
<br />
<b>Purchase List (paid links):</b><br />
<div><a href="https://amzn.to/3qoSMWx" target="_blank">1/8" plywood</a><br /></div>
<div><a href="https://amzn.to/2Ou4VMI" target="_blank">battery powered LED light string</a></div><div>(2) Double-A batteries <br /></div><div><a href="https://amzn.to/3v1CCpG" target="_blank">flat black spray paint </a><br /></div><div>paint (optional) - red, green, brown <br /></div>
<div></div>
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<b>Subtotal: $73 </b>($50 of that is plywood.<b> </b>whether you buy a 4'x8' sheet of ply or a pack of smaller sheets, you could make multiple shadow boxes from the amount bringing the individual cost down or you might have scrap on hand)<br /><b></b></div>
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<br /></div>
<div>
<b>Tool List:</b></div>
<div>
table saw with crosscut sled<br />band saw</div><div>files <br /></div><div>router, 1/8" bit<br /></div><div>orbital sander</div><div>chisel</div><div>hot glue gun</div><div>drill, drill bits</div><div>wood glue</div><div>clamps</div><div>duct tape<br /></div>
<div>
<br /></div>
<div>
<b>Cut List (approximate):</b></div>
<div>
(2) 12x10 [top & bottom]<br /></div>
<div>
(2) 8x10 [sides]<br /></div>
<div>
(2) 12x8 [inside walls]<br /></div>
<div>
(2) trees</div>
<div>letters 'J', 'O', 'Y'</div><div>Mary, Joseph, Jesus, star<br /></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I started this in Sketchup to get an idea of relative size of the pieces and to figure out how big the box needed to be. <br /></p><p>It's 12"x8"x10" deep with a false back wall to hide the wiring for the lights. Tracks are routed into the bottom to add surface area to glue the figures and letters. I did cut gussets for all the figures for extra support. I used wood glue and hot glue for all the pieces, the hot glue holding them in place for the wood glue to set.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Boxes</b></span><br />
I made the boxes first. I routed the grooves into the bottom plate before glue up. There are also grooves on the side walls for the tree and interior plate and a groove in the top plate for the interior plate The interior wall ensures the box glues up square. Dry fit everything and trim/sand as needed. Wipe away excess glue after clamping the box together lightly. Don't cinch it down. Any glue not wiped away will need to be removed with a chisel later.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZljJG1_N4EItCkxzij7WERM0A4aJfB169iHV0lCLxyE8WSw4DawoC8WshHTup7_zLaW7MSKiN5TNTVMcx0CE7dQVFYUMyu4vL_nzGX2dOgGHkVOszAKJkrW5O2vZFKboz83rltpiXGQU/s640/IMG_4295+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZljJG1_N4EItCkxzij7WERM0A4aJfB169iHV0lCLxyE8WSw4DawoC8WshHTup7_zLaW7MSKiN5TNTVMcx0CE7dQVFYUMyu4vL_nzGX2dOgGHkVOszAKJkrW5O2vZFKboz83rltpiXGQU/w400-h300/IMG_4295+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMf6m2Q48kHJTkTsB5137zHJCMpajLC4IXZ_jd9r4Xepb5-wDTUun2GDaB6G5R2g8xO1UY91gcb5NUHE70XBgTRpNgRCykqh22n93gDp3TvlwBjgHSP0RFOs6-Ulhb_QgxcOsQ80XGWIo/s640/IMG_4296+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMf6m2Q48kHJTkTsB5137zHJCMpajLC4IXZ_jd9r4Xepb5-wDTUun2GDaB6G5R2g8xO1UY91gcb5NUHE70XBgTRpNgRCykqh22n93gDp3TvlwBjgHSP0RFOs6-Ulhb_QgxcOsQ80XGWIo/w400-h300/IMG_4296+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyuqx1TUKW1IBTXgS1XpUIeAw_b-UrAvZPWByAE-NE-tlxXnEHCar505onwxUYaKKM37SufXv90Xb17yNR00zIvf4iS_JR8q4SezHZGxU1ndhIsys70mFW3mwKnYUkZNIetKW8f7Bc3ic/s640/IMG_4299+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyuqx1TUKW1IBTXgS1XpUIeAw_b-UrAvZPWByAE-NE-tlxXnEHCar505onwxUYaKKM37SufXv90Xb17yNR00zIvf4iS_JR8q4SezHZGxU1ndhIsys70mFW3mwKnYUkZNIetKW8f7Bc3ic/w400-h300/IMG_4299+copy.jpg" width="400" /></a></div><p>Test fit everything before glue up to make sure joints are tight. Once glued up, sand the faces and edges so it's smooth.<br /></p><p>For
the back wall, I added blocks to act as stops for the back wall. I want it semi removable. The
back wall has a notch cut out for the battery box which is tension fit. The battery box extends past the back wall just so you can grab it and pull it out to replace batteries.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUv-JchQK8RAyCBO5RthOF_qpYZPfA3FsG3sNpqVYuOw4Kg0mMLEqIhtKd6UNu_ZqlNGHNalXfWUs1sglsx5u-D35sEcqKHIs6tCA3GEtKDdV6bpb0oWMpeT6HAVF3o1jDahnCrK47yOI/s640/IMG_4298+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUv-JchQK8RAyCBO5RthOF_qpYZPfA3FsG3sNpqVYuOw4Kg0mMLEqIhtKd6UNu_ZqlNGHNalXfWUs1sglsx5u-D35sEcqKHIs6tCA3GEtKDdV6bpb0oWMpeT6HAVF3o1jDahnCrK47yOI/w400-h300/IMG_4298+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXcLjNNTyEFEzHfl0PCq8OfvZOFz9XEgICYb0cUm0qEyb9wY0pTqQQPYY5cbVKcjNvmsxcnCrqCP7CFxLoQsxLrS1Rcs1E7Uq-2MheOSkxSahVFBM8AKrfr7mI32pxyfA1S-PZoKbsPSw/s640/IMG_4297+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXcLjNNTyEFEzHfl0PCq8OfvZOFz9XEgICYb0cUm0qEyb9wY0pTqQQPYY5cbVKcjNvmsxcnCrqCP7CFxLoQsxLrS1Rcs1E7Uq-2MheOSkxSahVFBM8AKrfr7mI32pxyfA1S-PZoKbsPSw/w400-h300/IMG_4297+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis4rLQaFRcPQfLMfWy5EDUFsPEMp2EsYJNLFn-uDXxX3HntFlKjX006kvSnyrd9Ya9Ref0120VtDcZ27Fcb1_T_0ydhzpNYJxtxaZduKeieSHzYQfaiaPSqyHGN02t1lohAyWloVtCFBY/s640/IMG_4329+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis4rLQaFRcPQfLMfWy5EDUFsPEMp2EsYJNLFn-uDXxX3HntFlKjX006kvSnyrd9Ya9Ref0120VtDcZ27Fcb1_T_0ydhzpNYJxtxaZduKeieSHzYQfaiaPSqyHGN02t1lohAyWloVtCFBY/w400-h300/IMG_4329+copy.jpg" width="400" /></a></div><p><span face=""arial" , "helvetica" , sans-serif"><b>Figures</b></span><br />I
sketched the project in Sketchup first to get an idea of size it. Here
is the template I used to cut out the figures on the band saw.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKJ3E1KXCyMlJxalmhaGJ69x7z3J563ug6klGbTtNM6uquCcGGaqaINdND5MxBBMpBHhQffYc09BDQhFhGxk6i5P9bdezhznMeq8Uugmrl1_sCBm0SdmWef-Thv1XM1ZBrhUmqPHavvmM/s2000/JoyShadowBox.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1168" data-original-width="2000" height="234" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKJ3E1KXCyMlJxalmhaGJ69x7z3J563ug6klGbTtNM6uquCcGGaqaINdND5MxBBMpBHhQffYc09BDQhFhGxk6i5P9bdezhznMeq8Uugmrl1_sCBm0SdmWef-Thv1XM1ZBrhUmqPHavvmM/w400-h234/JoyShadowBox.png" width="400" /></a></div><p>I
tried to cut as close as possible to the lines while not cutting into the outline.
Flat and round files can knock down any rough spots and fix any
potential mistakes in cutting.</p><p>I cut small gussets out of the 1/8" ply to support the figures. The gussets are roughly 1"x3/8".</p><p><b>Paint</b><br />I wanted the outside of the box to remain unpainted, so I taped it and painted the inside black.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDkTSiOW4qDK4B5_iJbLF1Msqz-4GIPLvGybuRuLf08coWUjv4qVK-HknhzBeQ7C-tQu9zfYvaOmrEYQExFu81HPyh0s8y0fuCZ_Jdz-OW_Eu9rmzwO4AqfynNqr-qBwH5VmntoAYPuC4/s640/IMG_4331+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDkTSiOW4qDK4B5_iJbLF1Msqz-4GIPLvGybuRuLf08coWUjv4qVK-HknhzBeQ7C-tQu9zfYvaOmrEYQExFu81HPyh0s8y0fuCZ_Jdz-OW_Eu9rmzwO4AqfynNqr-qBwH5VmntoAYPuC4/w400-h300/IMG_4331+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqwmOSuIM9J5uyPMzDMUxFREn2EgcV9Fx2j6hpy9Z_XVcyKp5swN0C0pxNFeDBKXNhH82gcVZwwLwsnPfeZ07_u_WafWZX8yewzZW4VZAbHqnSFyAqvaKzFyonqHhZzG2WHxavxxbCNHY/s640/IMG_4332+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqwmOSuIM9J5uyPMzDMUxFREn2EgcV9Fx2j6hpy9Z_XVcyKp5swN0C0pxNFeDBKXNhH82gcVZwwLwsnPfeZ07_u_WafWZX8yewzZW4VZAbHqnSFyAqvaKzFyonqHhZzG2WHxavxxbCNHY/w400-h300/IMG_4332+copy.jpg" width="400" /></a></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Lights</b></span><br />There are eight LEDs on the string of lights. I drilled an 1/8" hole (check your LED size) into the back wall and then hot glued the lights into place from behind. I duct taped the wire to the back wall just to avoid tension on the lights.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR_POjIueL9xwfpMXVMAiLhXRN12_xKrKUKAlTNFe_I-CTUvnhT1V0uOkNuvFlDU9J6LkIgk9DKb2w4_s7x6T2bVIxoqYFtKmtY7Z3BNv1UMiTrTv6fpCKKOw5zGxAr183Hg05HBrkR4U/s640/IMG_4328+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR_POjIueL9xwfpMXVMAiLhXRN12_xKrKUKAlTNFe_I-CTUvnhT1V0uOkNuvFlDU9J6LkIgk9DKb2w4_s7x6T2bVIxoqYFtKmtY7Z3BNv1UMiTrTv6fpCKKOw5zGxAr183Hg05HBrkR4U/w400-h300/IMG_4328+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4T9NF_trN_7bJ5tgTM9VoEcy1JEbx09bn6OzWmq2JLbD63ID9m_w8WIp_rzl1-PkrF69nYounqwjPleVJKFgBRPrysRSmtM06VuhrfHG3Tpm5-3__CkaM117TShRFYVBuVKkIGUu9koU/s640/IMG_4333+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4T9NF_trN_7bJ5tgTM9VoEcy1JEbx09bn6OzWmq2JLbD63ID9m_w8WIp_rzl1-PkrF69nYounqwjPleVJKFgBRPrysRSmtM06VuhrfHG3Tpm5-3__CkaM117TShRFYVBuVKkIGUu9koU/w400-h300/IMG_4333+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjXEbtV0EoLLoCb3PEXr3TWsc3hCgJ4KCXt25U0FrmSUCy9rTxTt3ivSfvAm0yhn5qoehoSSIQuk9NZNYwvflD9UFLhFZpKSHNDWUBAXd2Qo4pzdf-SqOMGUlAxuqB-HFuFBP7pXdqBKI/s640/IMG_4335+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjXEbtV0EoLLoCb3PEXr3TWsc3hCgJ4KCXt25U0FrmSUCy9rTxTt3ivSfvAm0yhn5qoehoSSIQuk9NZNYwvflD9UFLhFZpKSHNDWUBAXd2Qo4pzdf-SqOMGUlAxuqB-HFuFBP7pXdqBKI/w400-h300/IMG_4335+copy.jpg" width="400" /></a></div><p><span face=""arial" , "helvetica" , sans-serif">The back wall is hot glued in place. I want it somewhat removable in case the lights go bad or the hot glue bond lets go.<b> <br /></b></span></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Finish</b></span><br />I painted the trees and the joy letters, leaving everything else unpainted. <br /></p><p>I glued gussets to the backside of all figures. Since the bottom plate has tracks cut in, account for that when you glue the gussets. They can't be flush with the bottom of the figures.</p><p>The trees run full height, so test fit before install and trim if
needed. I used wood glue and hot glue on the figures. The hot glue holds
them in place so the wood glue can dry.<br /> <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6pAtvITgR8y7rJyrAUcNmsO11bwg3LUJz3A1PrZnbv197yIqnHsfgiZZZ-ruOZKLdzQ-vcBe-B86TpR7s3-vzAwhS9jxno5FdQf7Zmf9G4bmF0YXgkkSH2biVWEQnfoytieS1pz8JNhU/s640/IMG_4751.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6pAtvITgR8y7rJyrAUcNmsO11bwg3LUJz3A1PrZnbv197yIqnHsfgiZZZ-ruOZKLdzQ-vcBe-B86TpR7s3-vzAwhS9jxno5FdQf7Zmf9G4bmF0YXgkkSH2biVWEQnfoytieS1pz8JNhU/w400-h300/IMG_4751.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia4brriC_hfHPjEggeEp_ZGD77MQsdRXEfSoighEt7T-WcesShXYIBo6KI7j3SDW2Rtj83W6xtAJ80h7ea9LhLKDl1YH8ecaNAiE1MvRJL8Y4hr9QTgc5_QR5qlRN732TY0GPPz0bLGms/s640/IMG_4750.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEia4brriC_hfHPjEggeEp_ZGD77MQsdRXEfSoighEt7T-WcesShXYIBo6KI7j3SDW2Rtj83W6xtAJ80h7ea9LhLKDl1YH8ecaNAiE1MvRJL8Y4hr9QTgc5_QR5qlRN732TY0GPPz0bLGms/w400-h300/IMG_4750.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieSkFLDkTMMLEKUlR5HI3JqUtc_m5uu4DCo4iYXnpxcIBktwwXE-csvpE29_q0PUVCnjlvHUW26SKSzhnbNWAh0FjLir_sjROolLUgLIsjAgkmuzcr_zQTxeX_w0QeijVXhXlWN6nv_kY/s640/IMG_4749.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieSkFLDkTMMLEKUlR5HI3JqUtc_m5uu4DCo4iYXnpxcIBktwwXE-csvpE29_q0PUVCnjlvHUW26SKSzhnbNWAh0FjLir_sjROolLUgLIsjAgkmuzcr_zQTxeX_w0QeijVXhXlWN6nv_kY/w400-h300/IMG_4749.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb0lHkbZMIJtYNmNW1fFdbZsrof-sVRICNt7cxvGWRplJ6-6uEZnI2gN1KFoqkAxeHmd9Kj3KZvCdQuqTGozBaDxU71CRmvsmGijLuzzPHUKje42QmbaoNFhCDUUd-_fKC6A1b_ktf7pA/s640/IMG_4748.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb0lHkbZMIJtYNmNW1fFdbZsrof-sVRICNt7cxvGWRplJ6-6uEZnI2gN1KFoqkAxeHmd9Kj3KZvCdQuqTGozBaDxU71CRmvsmGijLuzzPHUKje42QmbaoNFhCDUUd-_fKC6A1b_ktf7pA/w400-h300/IMG_4748.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmjI7_VFzB51hlJ7JAz3cyvisB6TVV5E6xs529zs1L1sk139e6-DxoedLn1r4Ur93-39g99iSAPJfKvMCRbx9_RbAMpMMcl3bul-C6I07yJ4UvLmETDOlOraMFXC-khPvvHk2zCNBkMl0/s640/IMG_4338+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmjI7_VFzB51hlJ7JAz3cyvisB6TVV5E6xs529zs1L1sk139e6-DxoedLn1r4Ur93-39g99iSAPJfKvMCRbx9_RbAMpMMcl3bul-C6I07yJ4UvLmETDOlOraMFXC-khPvvHk2zCNBkMl0/w400-h300/IMG_4338+copy.jpg" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI_79gzp4w-763fYmRU0tFps8viBD_hR38IKhqCDk5v_dzluDY3XXq9wYZHso5RbuvQG_6WwjyJ5plciRl-_IaeFGrTms_rYgvvL7yC_tfhygxaTdmsOhCldK4qsh4LLy7qIVZQxy3x7g/s640/IMG_4339+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgI_79gzp4w-763fYmRU0tFps8viBD_hR38IKhqCDk5v_dzluDY3XXq9wYZHso5RbuvQG_6WwjyJ5plciRl-_IaeFGrTms_rYgvvL7yC_tfhygxaTdmsOhCldK4qsh4LLy7qIVZQxy3x7g/w400-h300/IMG_4339+copy.jpg" width="400" /></a></div><p></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-33196240189441700332020-12-04T02:00:00.054-05:002020-12-04T02:00:06.610-05:00Baseball Bat Display Tension Brackets<span face=""arial" , "helvetica" , sans-serif"><b>Baseball Bat Display Tension Brackets</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWO12DIa1NuvDGB2bAVnBQjBXrgPThCHp2uhBKIv21N3njCJYk0LLRVluPaGkZdVHPlJ-5ehxltIU5kxhR6L5F__S1TOczoS2RY1QYpZmWBWu2AzYDZZLunEBzlyuDXuaJwinOQjwlIfM/s640/IMG_4258.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWO12DIa1NuvDGB2bAVnBQjBXrgPThCHp2uhBKIv21N3njCJYk0LLRVluPaGkZdVHPlJ-5ehxltIU5kxhR6L5F__S1TOczoS2RY1QYpZmWBWu2AzYDZZLunEBzlyuDXuaJwinOQjwlIfM/s16000/IMG_4258.jpg" /></a><br />I wanted to hang this bat off an existing shelf. These tension brackets I came up with don't require any extra hardware.<br />
<br />
<a name='more'></a>I wanted low key brackets that would allow easy removal of the bat.<br />
<br /><div>
<b>Tool List:</b></div>
<div>band saw, a jig saw would also work</div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I sketched an idea in Sketchup for the bracket. A c shape clips the bracket to the shelf, and a foot contacts the bottom of the shelf to prevent rotation.</p><p>The brackets are dissimilar because the bat has a 1" diameter at one bracket location and 1 7/8" at the other bracket. This also requires that the bracket's distance between the shelf and bat are dissimilar as I wanted the bat close to the shelf.<br /></p><p>I cut a proof of concept out of 1/8" plywood with the idea I would cut the finished brackets out of 3/4" plywood. I cut them out with a band saw.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhShN9C4ob6A0mnsm2LF0naQKJ3Zd06rxSKl0yf4lzuHaXHISormFiDi-zYi5JuUagScrOw77xBM6YUKygdAL-OkOMZC1kHub4KqIEwsj0tFS8pLvckK6AXIp8sIVwjuw5bX1KFDapcUDc/s640/IMG_4251.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhShN9C4ob6A0mnsm2LF0naQKJ3Zd06rxSKl0yf4lzuHaXHISormFiDi-zYi5JuUagScrOw77xBM6YUKygdAL-OkOMZC1kHub4KqIEwsj0tFS8pLvckK6AXIp8sIVwjuw5bX1KFDapcUDc/s16000/IMG_4251.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Iteration #1<br /></td></tr></tbody></table><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg08K0-YEVcLY_ZVBDnh21IDHQLBUOojANNzDv6y2z6fMogU6WPUtNdNlwFp9d2-R_MDU3mkXEev_rs4pevISOqst0g7O_QJLlrY1GiMN-pW55JDbl3WwUQwIvPpZgaRKJWpcKDix5iESQ/s640/IMG_4252.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg08K0-YEVcLY_ZVBDnh21IDHQLBUOojANNzDv6y2z6fMogU6WPUtNdNlwFp9d2-R_MDU3mkXEev_rs4pevISOqst0g7O_QJLlrY1GiMN-pW55JDbl3WwUQwIvPpZgaRKJWpcKDix5iESQ/s16000/IMG_4252.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Iteration #2<br /></td></tr></tbody></table><p>I didn't factor in the fact that the bat's weight is at the end of the
barrel. This makes the bat want to rotate around the larger bracket. I
was holding the bat in place when I made my measurements and didn't
realize the weight distribution. I recut the smaller bracket with the
hook on top to stop the bat from rotating. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsOZGrdwHBZC_Usf0bCU_j2q6NShrdUzWXfbSqNrAtsro0hOwD1l1U7Q6z3dyNegjURA0Ufu93jzS2QUZpJUigvm_K8ipImO5ZQKmNXe7rm6eVvd8Eooz8isnaUyECF676uLsvPxpAK4k/s640/IMG_4253.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsOZGrdwHBZC_Usf0bCU_j2q6NShrdUzWXfbSqNrAtsro0hOwD1l1U7Q6z3dyNegjURA0Ufu93jzS2QUZpJUigvm_K8ipImO5ZQKmNXe7rm6eVvd8Eooz8isnaUyECF676uLsvPxpAK4k/s16000/IMG_4253.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXQW6HmlbYjkmB0Edcu1Yf9n_kUlGNtekEC6uipOhZutR3EAKxEAnCBg1a5uGf_mfa5dal2f3clYgu3FzxVj-VXGihHK861JzzfT6ZtbnFXEo1Q6WTcPoBFIdbuqVb-aDFi-BwaI5B7IE/s640/IMG_4254.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXQW6HmlbYjkmB0Edcu1Yf9n_kUlGNtekEC6uipOhZutR3EAKxEAnCBg1a5uGf_mfa5dal2f3clYgu3FzxVj-VXGihHK861JzzfT6ZtbnFXEo1Q6WTcPoBFIdbuqVb-aDFi-BwaI5B7IE/s16000/IMG_4254.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwZR3mME3uQ3pTgExUusG_8vlY430dfdPu6UZMF7ISPSYUGrj75rhcC2Z9hEKM0S7e0429aNrzzcByq4RdKyaxGWqV5DuP3coc7fbLsdQZxZs-Fa4B5HqcoriQHNE-kvWcIRCw23PWKy4/s640/IMG_4255.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwZR3mME3uQ3pTgExUusG_8vlY430dfdPu6UZMF7ISPSYUGrj75rhcC2Z9hEKM0S7e0429aNrzzcByq4RdKyaxGWqV5DuP3coc7fbLsdQZxZs-Fa4B5HqcoriQHNE-kvWcIRCw23PWKy4/s16000/IMG_4255.jpg" /></a></div>I liked the thinness of the 1/8" plywood enough that I used the proof
of concept as the final product. Gravity keeps the brackets in place.
While weight pushing the smaller bracket down instead of pulling it up
would make it more stable, the L shape of the shelf mitigates the issue.The brackets and bat are completely stable.<br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTFPgnFVAbkyiF-0lAJXuAeUeIj3Tb8iSgJR4OuYXcZZ7o9N_nE9IcCu9qmUi4E-k70OOWzZHS85E053iDNogGOW6fYfJSNIQ1fq-MxuvTeiIhiqTWC7zQRSVOxJjgCHI-qA2q1WbvOsU/s640/IMG_4256.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTFPgnFVAbkyiF-0lAJXuAeUeIj3Tb8iSgJR4OuYXcZZ7o9N_nE9IcCu9qmUi4E-k70OOWzZHS85E053iDNogGOW6fYfJSNIQ1fq-MxuvTeiIhiqTWC7zQRSVOxJjgCHI-qA2q1WbvOsU/s16000/IMG_4256.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf6iqHKTDjcm7ZMJTQFub4YeYBqNX-j6U4GrZdknsL6hCkIOEFO0XoRz1vYKOdIut0M_0KSTqRyBOP4j5RAyi5Fy-PUNzfPjZzS-Bt14j2MVj-l4QensxVCd0GY1WApBC40ll3Tilpbbc/s640/IMG_4257.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf6iqHKTDjcm7ZMJTQFub4YeYBqNX-j6U4GrZdknsL6hCkIOEFO0XoRz1vYKOdIut0M_0KSTqRyBOP4j5RAyi5Fy-PUNzfPjZzS-Bt14j2MVj-l4QensxVCd0GY1WApBC40ll3Tilpbbc/s16000/IMG_4257.jpg" /></a></div><p></p><p>If you're wondering who signed the bat, it's career minor leaguer <a href="https://www.baseball-reference.com/players/w/willigl01.shtml" target="_blank">Glenn Williams</a>. When he signed the bat he was in his first year of pro ball with the Danville Braves, a rookie affiliate with Atlanta.<br /></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-1450426932218662082020-12-02T02:00:00.091-05:002021-03-05T12:50:44.461-05:00Air Hose Reel Mount<span face=""arial" , "helvetica" , sans-serif"><b>Air Hose Reel Mount</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDI226BXK12PicdKiN-CsjhL-CTdIkJId00hVI762C7AgEAOjy7yZxXRMgJWYa0UKXW63WcoqiOWutfYCxjO6bpmnzfFWsbh3EinTq627Bd5l93HwOu9_YVSpUZphpixgfcec46EfaRCg/s640/IMG_4217.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDI226BXK12PicdKiN-CsjhL-CTdIkJId00hVI762C7AgEAOjy7yZxXRMgJWYa0UKXW63WcoqiOWutfYCxjO6bpmnzfFWsbh3EinTq627Bd5l93HwOu9_YVSpUZphpixgfcec46EfaRCg/s16000/IMG_4217.jpg" /></a><br />I wanted the hose reel mounted to my compressor. Here's how I did that.<br />
<a name='more'></a><p> I built the mounting plate out of scrap 3/4" plywood.<br /></p><div>
</div>
<div>
<b>Tool List:</b></div>
<div>
table saw with crosscut sled<br />drill</div>
<div>
<br /></div>
<div>
<b>Cut List:</b></div>
<div>
(1)14"x7" mounting plate</div><div>(1) 14"x3" top plate with a notch for the compressor's piping<br /></div><div>(4) 2"x2" triangular gussets </div><div>(2) 1"x2" mounting tabs</div><div>(2) 2"x2" C shape clips</div><div></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />This is my <a href="https://www.northerntool.com/shop/tools/product_200658815_200658815?cm_mmc=Google-pla&utm_source=Google_PLA&utm_medium=Air%20Tools%20%2B%20Compressors%20%3E%20Air%20Hoses%20%26%20Fittings%20%2B%20Air%20Hose%20Reels&utm_campaign=Ironton&utm_content=49587&&ds_e_ad_type=pla&gclid=Cj0KCQiAk53-BRD0ARIsAJuNhptLIQdNA28okHOnOaC0a78wu97BjUY7dE49xRczz2wRUAgYLNgTYqIaAt7AEALw_wcB&gclsrc=aw.ds" target="_blank">hose ree</a>l. I wanted it mounted to the compressor (<a href="https://www.homedepot.com/p/Husky-20-Gal-200-PSI-Oil-Free-Portable-Vertical-Electric-Air-Compressor-C202H/312074157" target="_blank">that looks similar to this</a>) so that the entire thing is portable. With the compressor's location on my shop, the reel mounted to the front made accessing the line easy.</p><p>My first idea was a big <a href="https://www.lowes.com/pd/AMERICAN-VALVE-1-1-4-in-to-1-1-4-in-dia-Galvanized-Split-Ring-Hanger/1244125?cm_mmc=shp-_-c-_-prd-_-plb-_-google-_-lia-_-142-_-plumbingconnectionsandsupport-_-1244125-_-0&placeholder=null&gclid=Cj0KCQiAk53-BRD0ARIsAJuNhpvimGCYjLg3beTHONZvLPNAjvp0-RdlTAlI4iU9X1oSTbGkz93kpQwaAmdDEALw_wcB&gclsrc=aw.ds" target="_blank">clamp ring bracket</a> out of plywood that 'hung' from the top of the compressor tank. My second idea was hanging the mounting plate from the handle. I made it out of foam core to double check clearances. Plywood will be thicker so take that into account.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi989vpuTrR5b9lJbGbRXWDC6eTqvt1_iqv-A2z8z0hPqZRh9dXUffZEZY4PQqRIEASfgUpzQSUNDR6QrXKVplSqTjyWsuLXs8rpdgIqf2Lqq3M9iIEGiWTCRWZ1_Wmwh8hl-1nc1h8M7Y/s640/IMG_4206.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi989vpuTrR5b9lJbGbRXWDC6eTqvt1_iqv-A2z8z0hPqZRh9dXUffZEZY4PQqRIEASfgUpzQSUNDR6QrXKVplSqTjyWsuLXs8rpdgIqf2Lqq3M9iIEGiWTCRWZ1_Wmwh8hl-1nc1h8M7Y/s16000/IMG_4206.jpg" /></a></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju1zXqK_3kMpoW_1ucttKLPV0hT5LFt-P_HEMMYjUkCFyONbQ1qWoDmzV_xvtBy6hYnAFpIYj3e9bFELIqJzjyPwVphBKuMHfsQXoiE56DszBOKil2pEikC-eD69rELBBiljz5Ged-xkw/s640/IMG_4205.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju1zXqK_3kMpoW_1ucttKLPV0hT5LFt-P_HEMMYjUkCFyONbQ1qWoDmzV_xvtBy6hYnAFpIYj3e9bFELIqJzjyPwVphBKuMHfsQXoiE56DszBOKil2pEikC-eD69rELBBiljz5Ged-xkw/s16000/IMG_4205.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Foam core concept<br /></td></tr></tbody></table><p>The top plate, mounting plate, and tabs form a 'Z' shape. The tabs straddle the handle. <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYuGHE6FKhOxI8S22DJP7Z5_fesizh2WcI3J_A44QrAiAHUnvDSQHODTGbST9M_8N3ReIZcOMCZc98a3oo5NONb7lRo4rtRsqQU89oHMv0VuLd8Q3YipuocuDcOJ06jufbTDUOQjINvFw/s640/IMG_4209.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYuGHE6FKhOxI8S22DJP7Z5_fesizh2WcI3J_A44QrAiAHUnvDSQHODTGbST9M_8N3ReIZcOMCZc98a3oo5NONb7lRo4rtRsqQU89oHMv0VuLd8Q3YipuocuDcOJ06jufbTDUOQjINvFw/s16000/IMG_4209.jpg" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzpWJG2veYaQAFdh9G8Y4FqvGfs3QSJLJzotzOBqHKWVbgUjIVSli5-kjtdFEnSJ_vdJu9_rAXTfBrOKetPvuxSLeDpWGgFxKcwSMmAqHzupvmbzJKYrAai_NAR5aXtYpzlm743xsdsYo/s640/IMG_4208.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzpWJG2veYaQAFdh9G8Y4FqvGfs3QSJLJzotzOBqHKWVbgUjIVSli5-kjtdFEnSJ_vdJu9_rAXTfBrOKetPvuxSLeDpWGgFxKcwSMmAqHzupvmbzJKYrAai_NAR5aXtYpzlm743xsdsYo/s16000/IMG_4208.jpg" /></a><br />Once the bracket is in place against the compressor, the C clips slide over the handle and are screwed to the tabs with 1" coarse thread screws. This locks the bracket in place. The tabs and mounting plate are gusseted for extra strength.<br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbrj_Xk4fWa2fmrI7XvLDSy_YbvrYkmAJqpc96pDn4LEwbnr0ZuddbkZmTMcrNFUJyMeL7BIZ7qvfpn5q8G4qvoNsW6_rZvA6EB32h8uSBdHAdBQhk-6CH7EzMGfY6UaYgUhKRuqGERBk/s640/IMG_4210.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbrj_Xk4fWa2fmrI7XvLDSy_YbvrYkmAJqpc96pDn4LEwbnr0ZuddbkZmTMcrNFUJyMeL7BIZ7qvfpn5q8G4qvoNsW6_rZvA6EB32h8uSBdHAdBQhk-6CH7EzMGfY6UaYgUhKRuqGERBk/s16000/IMG_4210.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Top plate, tab, c-clip, gusset.<br /></td></tr></tbody></table><p>I painted the bracket black to match the compressor.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5LK3A5Ga2Ancdy6Ig_BLaXV3T6wEiOgBGF2wNYoC0CawdEEqWI_CEWTowQoY4XEh7UNcVmY4e__GVClW1zZsKXql3DBNwuLREuRR9RIrFF_copaCJVDSS6Ya6CPnXWa6Oe0KnXRUpbSY/s640/IMG_4211.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5LK3A5Ga2Ancdy6Ig_BLaXV3T6wEiOgBGF2wNYoC0CawdEEqWI_CEWTowQoY4XEh7UNcVmY4e__GVClW1zZsKXql3DBNwuLREuRR9RIrFF_copaCJVDSS6Ya6CPnXWa6Oe0KnXRUpbSY/s16000/IMG_4211.jpg" /></a></div><p><br />I'm running a 50' 3/8" line. For all the hookups, you will need (1) set of 3/8" quick connects. The female quick connect for the 50' line and the male for the 3' whip. The whip connects the compressor to the reel. The reel has 1/2" fittings so I got (2) 3/8" to 1/2" adapters. I used thread tape on all connections.<br /> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCgnLDHz3cA6QID3Qn8voukBYa0b-cTHO2d39CgZkS-oAiu8RtEQdC1hxQnnk0ATlISwZUI87woKaoG3H8kPyfeRoyh0TN2O69Br8VU9kKzM2ZnoiwLtz2NzE6PTKUjx9x0940yTrVXbU/s640/IMG_4259+copy.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCgnLDHz3cA6QID3Qn8voukBYa0b-cTHO2d39CgZkS-oAiu8RtEQdC1hxQnnk0ATlISwZUI87woKaoG3H8kPyfeRoyh0TN2O69Br8VU9kKzM2ZnoiwLtz2NzE6PTKUjx9x0940yTrVXbU/s16000/IMG_4259+copy.jpg" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A finishing touch with a vinyl cutter.<br /></td></tr></tbody></table><br />WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-75268495178253093042020-11-02T02:00:01.213-05:002020-11-09T08:46:03.379-05:00The Mandalorian Costume Build<span face=""arial" , "helvetica" , sans-serif"><b>The Mandalorian</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNhL5oC7xu1CeUWPuUCHy3WQpNh5vJiqymPWvf89n3QNjhBRDG_QM6bO3BkvW70_4ELlVtTOCjizewfpDKLRtyTAit8BFISxoH1FaFysJzzkMtruBBjxpuKbfSiNoJMDRAitsEbnMBvac/s640/BlogCover.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNhL5oC7xu1CeUWPuUCHy3WQpNh5vJiqymPWvf89n3QNjhBRDG_QM6bO3BkvW70_4ELlVtTOCjizewfpDKLRtyTAit8BFISxoH1FaFysJzzkMtruBBjxpuKbfSiNoJMDRAitsEbnMBvac/s16000/BlogCover.png" /></a><br />I've thought about making a Boba Fett Halloween costume for years. When I watched <i>The Mandalorian</i> I knew this year's Halloween costume.<br />
<a name='more'></a><a href="https://crossthenetflixstream.blogspot.com/2020/06/the-mandalorian-season-1-review.html" target="_blank"><br />The Mandalorian</a> is a great show and the costume looks awesome. There's a lot of parts and I never have enough time with Halloween being the due date. I worked from the helmet down, knowing that people would look at the helmet first and hoping they wouldn't look at the boots in case I hadn't finished them.<br />
<br />
<b>Purchase List (paid links):</b><br />
<div></div><ul style="text-align: left;"><li><a href="https://amzn.to/3e8A153" target="_blank">Black coveralls</a></li><li><a href="https://amzn.to/34G5okt" target="_blank">Chelsea ankle boots</a></li><li><a href="https://amzn.to/3jFWfNd" target="_blank">Black motorcycle gauntlet gloves</a></li><li><a href="https://amzn.to/34EOanx" target="_blank">Industrial safety gloves</a></li><li><a href="https://amzn.to/2TOkKNL" target="_blank">Face shield replacement</a></li><li><a href="https://amzn.to/37RUeep" target="_blank">EVA foam floor mats (4 pack)</a></li><li><a href="https://amzn.to/37QKMb5" target="_blank">Craft foam</a> </li><li><a href="https://amzn.to/3kASdXz" target="_blank">Leather scraps</a></li><li><a href="https://amzn.to/37PSFxC" target="_blank">Grey wool blanket</a></li><li><a href="https://amzn.to/3e6lTJP">Muslin perm press material</a></li><li><a href="https://amzn.to/385ThiX" target="_blank">Styrene plastic .04</a></li><li><a href="https://amzn.to/31UCqvi" target="_blank">1/2" Conduit </a></li><li><a href="https://amzn.to/3oSnwzH" target="_blank">Wood skewers </a></li><li><a href="https://amzn.to/32b4qLv" target="_blank">Aluminum plate 14 ga.</a></li><li><a href="https://amzn.to/2JwQ3L0" target="_blank">Aluminum angle 2"x2"</a><br /></li><li><a href="https://amzn.to/3kX0Sne" target="_blank">3/16" Pop rivets</a></li><li><a href="https://amzn.to/3oTaemw" target="_blank">1/8" Pop rivet</a> <br /></li><li><a href="https://amzn.to/3619iE4" target="_blank">Snap buttons </a></li><li><a href="https://amzn.to/34PVUmP" target="_blank">1" hook & loop non-adhesive velcro</a></li><li><a href="https://amzn.to/3oRB2Ub" target="_blank">Acrylic caulk</a></li><li><a href="https://amzn.to/383nXBf" target="_blank">Half-time filler </a></li><li><a href="https://amzn.to/2JxrugZ" target="_blank">Plasti-dip spray paint (2) cans</a></li><li><a href="https://amzn.to/3mLPZFs" target="_blank">Rustoleum spray paint</a> (1) can each (7 total): satin Chestnut Brown, Flat Red, metallic silver, satin Smokey Beige, satin Oasis Blue, metallic Bronze, stain Granite<br /></li><li><a href="https://amzn.to/386lh5P" target="_blank">Acrylic paints</a>: black, white, brown, silver</li></ul>
<div>
<b>Total: $418 / I spent $186 as I already had a lot of this stuff<br /></b></div><div><b> </b><br /></div>
<div>
<b>Tool/Supply List (paid links):</b></div>
<ul style="text-align: left;"><li>pencil (I prefer a <a href="https://amzn.to/3jXMA4p" target="_blank">lead holder</a>)</li><li>marker</li><li>chalk<br /></li><li>scrap paper for sketching and for protecting work surfaces<br /></li><li>painters tape</li><li>duct tape </li><li>hobby knife with replacement blades</li><li>metal straight edge <br /></li><li>cutting mat</li><li>band saw</li><li>hack saw </li><li>file</li><li>rasp </li><li>drill with 1/8", 3/16" bit</li><li>dremel and sanding bit and cutting disk<br /></li><li>sanding block/220 grit paper</li><li>heat gun to seal foam<br /></li><li><a href="https://amzn.to/366f2wq" target="_blank">wood burning tool</a> to create battle damage in foam<br /></li><li>sewing machine, black thread, white thread</li><li><a href="https://amzn.to/3kSs8DC" target="_blank">seam ripper</a></li><li><a href="https://amzn.to/3eq3GXQ" target="_blank">rotary cutter</a></li><li><a href="https://amzn.to/383Dxgh" target="_blank">leather punch </a></li><li>contact cement</li><li>hot glue/hot glue gun</li><li>crazy glue </li><li>wood skewers for stirring contact cement, painting hard to reach crevices<br /></li><li>black shoe polish <br /></li><li>paint brushes</li><li>shop towels</li><li>respirator with organic vapor cartridges - contact cement is toxic, so is spray paint</li></ul>
<div>
</div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />I started with <a href="https://imgur.com/gallery/2a7rXy7#mowXXvW" target="_blank">reference photos</a>. I'm recreating the pre-Beskar armor. I like weathered and beat up props, and they're more fun to make. Plus I know I don't want to pay for a good looking chrome finish like Alclad and it takes time to get an automotive quality finish. I don't have time to sand/prime/sand for that perfect look.<br /></p><p>I planned to work from
head to toe, because the helmet is the most important part of the
costume. Without that, the rest doesn't matter.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAhCAA5zibk-lONHzaSd487S1tjNSBymjCj8RhMXi72OfVH103ZgcJW6InJjm-DeeK657TeoAq_m6J2q-aDWfNkt7HDqYLg326eVAEJ_L5EnT4r2WExNopuNDXxwNp2fAmjSCP4NT12K0/s640/IMG_3497.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAhCAA5zibk-lONHzaSd487S1tjNSBymjCj8RhMXi72OfVH103ZgcJW6InJjm-DeeK657TeoAq_m6J2q-aDWfNkt7HDqYLg326eVAEJ_L5EnT4r2WExNopuNDXxwNp2fAmjSCP4NT12K0/s16000/IMG_3497.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I sketched each part of the costume before building it.<br /></td></tr></tbody></table><p>I used Punished Prop's <a href="https://www.punishedprops.com/2019/11/11/foam-mandos/" target="_blank">Mandalorian helmet template</a>. Everything else, I sketched a template on paper based on reference photos.<br /></p><p>The armor is foam. It's an easy and forgiving medium. While floor mats are the cheapest option, the EVA foam geared for cosplay can be nicer and doesn't have the imprinted pattern on the back. At some point you will be sanding through the pattern because you need a flat surface.</p><p>I use contact cement to glue the foam. Wear a respirator! With foam being porous, you'll need two coats to prep it correctly. Wait for the contact cement to dry completely before gluing. You only get, one shot to glue it. <br /></p><p>I used a sharpie to transfer patterns to the foam, tracing around the paper patterns.<br /></p><p>I used styrene depending on thickness of the item, including the hand guards and shin armor.</p><p>This is a month of work, working most nights/weekends.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Foam - Helmet</b></span><br />
I would have liked to use styrene or resin for the helmet, but I don't
have a way to shape styrene or a quick way to build a helmet to cast in
resin. A rigid helmet is the best way to get a screen accurate prop with
an automotive level finish. </p><p>I knew what the finish would be on the helmet, and it's decent for foam.</p><p>Punished Props template makes quick work of building the helmet. The template even has registration marks for alignment. My only tip would be to pay attention to cuts/intersections. An angled cut depending on the curve/placement will get a cleaner joint. My joints around the dome were straight cuts, and the joint protrudes a bit, and thus I had to sand it down for a more even finish. An angled cut would have been more conducive to the curve of the dome. </p><p>I printed the templates, cut them out, then traced them in marker on the foam, adding the registration lines too. Those lines are a great help in putting it together.<br /></p><p>I use contact cement to join foam. It's more effective than hot glue, doesn't produce thin strings of glue over everything, and doesn't add thickness. With contact cement, you don't get any working time. When you mate two surfaces they are stuck very well. If you mess up, you'll have to cut the pieces apart.<br /></p><p>It helps to pre-curve pieces before glue up. You can heat treat them at this point or just shape by hand/on the corner of a bench.</p><p>The cheek pieces were cut on the band saw at a ~40 degree angle which gives them the inset. <br /></p><p>I bevel cut the bottom edge of the helmet on the inside so it wouldn't look so thick and be a give away this is a foam helmet. I didn't bevel the visor cut out as the bevel would cause the visor piece to not sit flush. I could have done a rabbit, but it's difficult to cut a rabbit in foam with a consistent thickness.</p><p>I hot glued a temporary piece of foam to help shape the front as it lacks rigidity. The visor will help that. The ear pieces, top strip and rear vent are craft foam. The bevel on the ears is difficult with foam. I cut an angle on the band saw then sanded it smooth. I broke the ears into individual pieces and then assembled. Trying to build it as a one off is too complicated. A dremel/sanding bit rounds off edges as needed.<br /></p><p>I sanded all joints as some of them were pinched/puckered. Angled cuts would have helped here.</p><p>The horizontal portion of the visor has a lip above it. I used craft foam to create the lip, and cut into the helmet at the bottom of the visor opening to blend this lip as it's only raised above the visor.</p><p>For the top strip, I used craft foam as a base and another scored for the actual strip on top of it to give it the right thickness. <br /></p><p>If you haven't heat treated the foam, do that prior to plasti-dip. The foam will darken very slightly. If it darkens a lot, you're burning it. I used acrylic caulk over all the joints. A cup of water and my finger smooth out the joints and make them smooth. If I were doing this again, I might go over the entire helmet with watered down acrylic caulk. That would produces a smoother finish. <br /></p><p>Since the helmet should have a paint finish, I used Half-time filler over the joints and in a few rough spots. As soon as it flashes and becomes solid, start sanding. It's easier to sand at that stage than when fully cured.<br /></p><p>I did a base coat of plasti-dip and three coats of silver before adding the visor. I left the helmet outside after the Plasti-dip in the shade and the sun rose, leaving a portion of the helmet in the sun. This caused bubbles in the Plasti-dip and loosened a dome seam. I glued the seam back, cut the bubbles out and used Half-time to fill it. You can tell where I had bubbles after paint, but it looks better than it could have.<br /></p><p>I created a template for the visor then cut the face shield large, trimming little by little before it fit. Then I tacked it in a few places with hot glue before using contact cement. I did sand the edges of the visor with 200 grit paper just to give the glue some grip.</p><p>I added a piece of upholstery foam to each cheek and at the back of my head. This keeps the helmet still as otherwise it would move when I turn my head. I didn't add foam to the top as that would have raised the helmet too high.<br /></p><p>BE CAREFUL with contact cement on the visor, it will mar the plastic. I used acetone to clean it up, but it left a streak on the vertical portion. I might could have buffed that out. The other option is to use hot glue for the visor. It won't mar the visor and it will just peel off the visor. Hot glue can be pretty strong.<br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHzqkCjNkifh2RuuCCeDD98pCXtl7P3fz4umvW8yvN6p9Ny6KqbFqZIGV8sFtNtLmEHVxZDLGD7BA1jW-0NuO7vkBjzWOAwsSpHDe0GJNrYTpWpwcLzJtZjvfq05mO410cHmcrV85dsbc/s640/IMG_3461.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHzqkCjNkifh2RuuCCeDD98pCXtl7P3fz4umvW8yvN6p9Ny6KqbFqZIGV8sFtNtLmEHVxZDLGD7BA1jW-0NuO7vkBjzWOAwsSpHDe0GJNrYTpWpwcLzJtZjvfq05mO410cHmcrV85dsbc/s16000/IMG_3461.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I created the helmet from EVA foam floor mats.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz9T9pEcw2_K6B7pIk5foL7GKMvnpWg5AZzsYm22jAHkx26_mnomSZpuIu54awW1SHArUSPiOiOKA9zCn6uLUH-5vcPZk21po18i85gbxSa_Yitjl0J0hdFqasI4pmZyJ6C601hNDs7T0/s640/IMG_3462.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz9T9pEcw2_K6B7pIk5foL7GKMvnpWg5AZzsYm22jAHkx26_mnomSZpuIu54awW1SHArUSPiOiOKA9zCn6uLUH-5vcPZk21po18i85gbxSa_Yitjl0J0hdFqasI4pmZyJ6C601hNDs7T0/s16000/IMG_3462.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I labeled each piece while cutting to make assembly easier.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh1MBM87ERNeFEJVrEJBLpyPDkb4y-ow9uW0KvdajPOeonjRDprrpb0GypD3T6o_lQbtLn7Cu4dBN3hqjGA_PGc0MpjpEmB1tVvjJ5XtmFKaLkF-1L6m9GEPP4h10hcKG9wQo-gm6bTz4/s640/IMG_3464.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhh1MBM87ERNeFEJVrEJBLpyPDkb4y-ow9uW0KvdajPOeonjRDprrpb0GypD3T6o_lQbtLn7Cu4dBN3hqjGA_PGc0MpjpEmB1tVvjJ5XtmFKaLkF-1L6m9GEPP4h10hcKG9wQo-gm6bTz4/s16000/IMG_3464.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Contact cement attached the foam.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibRXe3-PLx3xQ1bLpi7K-BBu4sXHtZXdPzGjCF8kca0bOvW_j8kcCv0xK1WZL80cbtcEL8NliDtMwBPMnt09tEv4dvcxNZKzBlMy1TuzhNEk_HVIL-RLCrflDZt3PoYXZIr5YCe-wVq40/s640/IMG_3465.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibRXe3-PLx3xQ1bLpi7K-BBu4sXHtZXdPzGjCF8kca0bOvW_j8kcCv0xK1WZL80cbtcEL8NliDtMwBPMnt09tEv4dvcxNZKzBlMy1TuzhNEk_HVIL-RLCrflDZt3PoYXZIr5YCe-wVq40/s16000/IMG_3465.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The Punished Props template is based on Boba Fett so the cheek pieces are<br />rounded when they should come to a corner (bottom). It took a few tries to get the cut angle<br />correct, which was done on a band saw.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjK5H5q2ZB3SCT9r_aIXv15kRV0ZkxHM9nM52JzJpVCDf4rc_6NWY2WYCBa_41NIj8yY5px5ooUKJJeSDrgmqe1NC_N7-9mCGe1fTSreKHPWwvAiRf7-8HNfIzmHQ8SSf_LF3aKr6ZN80/s640/IMG_3466.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjK5H5q2ZB3SCT9r_aIXv15kRV0ZkxHM9nM52JzJpVCDf4rc_6NWY2WYCBa_41NIj8yY5px5ooUKJJeSDrgmqe1NC_N7-9mCGe1fTSreKHPWwvAiRf7-8HNfIzmHQ8SSf_LF3aKr6ZN80/s16000/IMG_3466.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I cut all the foam at a 90* angle, but it would have been better to angle it depending<br />on the joint to facilitate better attachment and avoid mild puckering.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcWYTIkcnZaJHlpuJKUJlvBuAxkuPW9jTG68pjOFNal7J76dIzQAb-dqFNqtIw5BCyKkSc_7ipuLJaaJdZ5mOk6zhOh3PQsUwTpFLQyvfvieKGUzxTUW7aj6miifSBtOkiUMoz2cbnxEE/s640/IMG_3468.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcWYTIkcnZaJHlpuJKUJlvBuAxkuPW9jTG68pjOFNal7J76dIzQAb-dqFNqtIw5BCyKkSc_7ipuLJaaJdZ5mOk6zhOh3PQsUwTpFLQyvfvieKGUzxTUW7aj6miifSBtOkiUMoz2cbnxEE/s16000/IMG_3468.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVzIeRNTLgtghv07JkKVipp1ME4yRoQBWiK2BSrKC93jjHGHpmj9O7o_ZvuowXntzqyZpkoN4XVlWIKfnr2QzN-adoy7yFcel_be2OKopXeazlZI2X2iS6T0zSqaITubyOCbc5PtE6T-Q/s640/IMG_3469.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVzIeRNTLgtghv07JkKVipp1ME4yRoQBWiK2BSrKC93jjHGHpmj9O7o_ZvuowXntzqyZpkoN4XVlWIKfnr2QzN-adoy7yFcel_be2OKopXeazlZI2X2iS6T0zSqaITubyOCbc5PtE6T-Q/s16000/IMG_3469.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A temporary piece of foam holds the front in place until the visor is glued in, otherwise the front is too flimsy.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsi9144m5AAFXRhUB2gL70O9Q1rlKG80R2IhleRC5Kg_kdhRtl4t_9NUCtb9j7nTutUQ6FuKV84ZLUxnJ4nobX-j3nTV8IElWeC9rCPB67ghxIMkrnnAFeBltrc1UImUgoVeUueQaLq2g/s640/IMG_3470.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsi9144m5AAFXRhUB2gL70O9Q1rlKG80R2IhleRC5Kg_kdhRtl4t_9NUCtb9j7nTutUQ6FuKV84ZLUxnJ4nobX-j3nTV8IElWeC9rCPB67ghxIMkrnnAFeBltrc1UImUgoVeUueQaLq2g/s16000/IMG_3470.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc_vZviyK8El9R3cF-Zr9A0Eg4RZJA-E9wJk-d_5l-S6tft6PIvlLYWhPHoUe2tN4BBV08olg-1ZzN6mtIE26S8xutczdnLgkT9iCzBWjeDMxPBMRp1EMfe71qEJhWdgBTNwjoce0FNvQ/s640/IMG_3471.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc_vZviyK8El9R3cF-Zr9A0Eg4RZJA-E9wJk-d_5l-S6tft6PIvlLYWhPHoUe2tN4BBV08olg-1ZzN6mtIE26S8xutczdnLgkT9iCzBWjeDMxPBMRp1EMfe71qEJhWdgBTNwjoce0FNvQ/s16000/IMG_3471.JPG" /></a></div><p></p><p><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZxZsNrejZT1L7EEZ43ZnA6O1P42ZlRXsHlCRru5vD5opBP7QAY9cfcr9e9xVQGevtrou88KgjGml4RX2pKV0TgjkNdYiYRaZGlFxq38ln1Tvm4kLHJUgCpBcwpY_gisYXDQjZz3UpnCo/s640/IMG_3474.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZxZsNrejZT1L7EEZ43ZnA6O1P42ZlRXsHlCRru5vD5opBP7QAY9cfcr9e9xVQGevtrou88KgjGml4RX2pKV0TgjkNdYiYRaZGlFxq38ln1Tvm4kLHJUgCpBcwpY_gisYXDQjZz3UpnCo/s16000/IMG_3474.JPG" /></a></b></span><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8v1rq6Z4qwavqM_B0A9IK9Tt7I_MsXbGVeK4AbV886d1i-uu_AFdDHev7ptG1313D9SEYMajWu6XBTqxItYpRFM_9ulpQFnfUScchmp9IFcAtbqE7RKmLAl4l5Q3_18qAy0_GkDU__Ys/s640/IMG_3475.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8v1rq6Z4qwavqM_B0A9IK9Tt7I_MsXbGVeK4AbV886d1i-uu_AFdDHev7ptG1313D9SEYMajWu6XBTqxItYpRFM_9ulpQFnfUScchmp9IFcAtbqE7RKmLAl4l5Q3_18qAy0_GkDU__Ys/s16000/IMG_3475.JPG" /></a></b></span><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih-_cHJiPR0oOinJ_kZnl6XwModppiwOSUwK1TfsJ6ssAibi7iOX1Sl4lifpKmkpueaAGPK4GjQyqJXJH9KCVsdDSEZNonGlTynsjA8CrimsLPou8xrtO0d8JUbyHbKFiEBUjjBhEWQk0/s640/IMG_3485.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih-_cHJiPR0oOinJ_kZnl6XwModppiwOSUwK1TfsJ6ssAibi7iOX1Sl4lifpKmkpueaAGPK4GjQyqJXJH9KCVsdDSEZNonGlTynsjA8CrimsLPou8xrtO0d8JUbyHbKFiEBUjjBhEWQk0/s16000/IMG_3485.JPG" /></a></b></span><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuMWts2GcnQAe1VeEZDmIUHaTUegOhj-AFKKoNgWiPI1QvSWJXgvrz0Yw23H2SuyNdYEihZodmeMyeTOAocgqR6C_zB225BbzAK21_7L3oWZU5V4K-6AB3BFJtpfKa-eEWgokQHFE9Fpw/s640/IMG_3493.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuMWts2GcnQAe1VeEZDmIUHaTUegOhj-AFKKoNgWiPI1QvSWJXgvrz0Yw23H2SuyNdYEihZodmeMyeTOAocgqR6C_zB225BbzAK21_7L3oWZU5V4K-6AB3BFJtpfKa-eEWgokQHFE9Fpw/s16000/IMG_3493.JPG" /></a>Foam - Chest Plate, Armor, Gauntlets, Leg Wrap</b></span><br />I
created paper templates for the pieces, then attached them to me, took a
picture, and modified as required. An eye test isn't always enough.
What looks good to the eye, may look small/large in an image.</p><p>Test fit wearing the flight suit. It can be a pain, but it ensures accuracy.<br /></p><p>With
the chest plate, I guessed on the size based on reference images and
where the belt and collarbone were, using those as references to size
the chest plate to me. Most of my templates had at least a few
iterations.</p><p>For the chest plate, I cut a beveled triangle on the
inside to create the curves around the perimeter and the curves around
the chest. The chest emblem is craft foam with a floor mat backing. A
dremel rounded all the edges. I used a sanding block too, if I needed to
feather edges when dremel wasn't doing it.</p><p>For the
shoulders, I used (3) pieces of foam with curved cuts so that piece
would curve around my shoulder when glued up. The right shoulder has (2)
strips of craft foam for seams.</p><p>The left shoulder has a trim that
I used a dremel on to get a bevel. I also dremeled the floor mat
pattern off of the foam so it would glue flat to the shoulder.</p><p>The
thigh armor is a single piece of foam. the trim is more foam floor mat.
I cut all joints tight and used the contact cement to get tight joints.
Gaps just don't look good.</p><p>For the foam armor trim I ripped the
foam on the band saw. To do this safely, use two pieces of plywood with
the foam sandwiched in between. <br /></p><p>The gauntlets are floor mats
as well. They look too big/thick, but too late to fix that. I built them
up piece by piece. I sized them to my arm in the flight suit, but not
to my arm in the jumpsuit AND glove. I had to add stretchers so they
would actually wrap my arm when wearing the gloves. I added a foam
triangular strip/flap with velcro on it to close the gauntlets.<br /></p><p>The
mini-missiles on the right arm are wood skewers. The circles on the
left are .04 styrene glued to a styrene plate that is recessed into the
foam. I used a leather punch on .04 styrene to get perfect circles. To
get the spacing right, I created a grid on paper, then put the circles
down in the right location. Very carefully I put painters tape over the
circles and caught each one. Stuck to the tape, the circles can't move,
so I then glued them to the plate.</p><p>The leg wrap is composed of
five pieces. The upper strip is two pieces of craft foam, one thinner
than the other for the banding. The top edge rolls over a piece of foam I
rip cut to give it a thicker look. The piece below that is craft foam. I
heated it up and then scrunched it down to simulate wrinkles. I had to
do this a few times. <br />Below that is a band, and below that is craft
foam scored every .5". I heated the bottom edge and flared it by just
pulling on the edge. Make the scores very thin. Heat will open them up
and the craft foam is thin to begin with. <br />These pieces are all glued
together so the leg wrap is a single piece. The velcro attaches at
different points. For the top band the velcro is at the outside of my
leg, behind the 4"x4"x1" craft foam pouch. The wrinkled piece of craft
foam has no velcro. The band below that has velcro on the front inside
portion of the leg. The scored wrap has velcro in the back. The velcro
placement differs so it could be hidden the best.<br /></p><p>After the
armor was done I heat treated and curved it to fit my body. I then used
reference photos to add damage with a wood burning tool. Be careful,
this can go right through foam, but it's great at creating pock marks,
scratches, and blaster impacts. The chest plate has two dominant blaster
impacts.<br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYYm_3i4WtvrNiLr-KCLt7W-JHhmFmPWeEPH6itBKnRqDy2oT6wM1v9fMhFfFpJop8xZZ59EXD_jBIfqmimAbIsfm5IxXxAquO_kIHMLOiOdrh4trpmeUR1gIGWhS14NQqK8x9mbJeFSE/s640/IMG_3472.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYYm_3i4WtvrNiLr-KCLt7W-JHhmFmPWeEPH6itBKnRqDy2oT6wM1v9fMhFfFpJop8xZZ59EXD_jBIfqmimAbIsfm5IxXxAquO_kIHMLOiOdrh4trpmeUR1gIGWhS14NQqK8x9mbJeFSE/s16000/IMG_3472.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I mimicked the curves in the helmet for the pauldrons.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWfCLZiqN9ak5Ko0m3rJjD1uP2C_IwqS8G9b4cm3h9j3MgpyN6GpNi9kZ8YSCru6htjsaR-UKQdDWde6_eJAiPFSX1IpUWZH9-_A3opJ23xA4Fd8C5B1S67YXbj-VVdeaagVBucqvWDNY/s640/IMG_3473.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWfCLZiqN9ak5Ko0m3rJjD1uP2C_IwqS8G9b4cm3h9j3MgpyN6GpNi9kZ8YSCru6htjsaR-UKQdDWde6_eJAiPFSX1IpUWZH9-_A3opJ23xA4Fd8C5B1S67YXbj-VVdeaagVBucqvWDNY/s16000/IMG_3473.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQgIvDf9ijxC6mTx_fOqAafZoCqkOWABtA7jOmgFBn5aQshOo5HtYGadFtYmYkCRok3rKsIlrWFroND15LK0-_pnVFdnmCJPrZLfI0qLBsuthoZytN1TrQ9b9Sb-90vA_GXqaVUbhesws/s640/IMG_3476.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQgIvDf9ijxC6mTx_fOqAafZoCqkOWABtA7jOmgFBn5aQshOo5HtYGadFtYmYkCRok3rKsIlrWFroND15LK0-_pnVFdnmCJPrZLfI0qLBsuthoZytN1TrQ9b9Sb-90vA_GXqaVUbhesws/s16000/IMG_3476.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A wood burning tool creates the blaster marks.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_c4dDOpAOSejpfzsO6xC1OABFEFvUayZyWlvVXYAFUyPdtPgW01Pv9wvOL_3HG3dmqoorEp5NQKD1MHT1MrpxNoHSGd8NVH63CKUNzwZKL53uFOyIVXmbOIcovU_ZMALGgpZaVkclCSo/s640/IMG_3478.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_c4dDOpAOSejpfzsO6xC1OABFEFvUayZyWlvVXYAFUyPdtPgW01Pv9wvOL_3HG3dmqoorEp5NQKD1MHT1MrpxNoHSGd8NVH63CKUNzwZKL53uFOyIVXmbOIcovU_ZMALGgpZaVkclCSo/s16000/IMG_3478.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnjl6bE60zR9StiujBmvuh8pN4NyKzcD5S3pkt-xlK3u_MZujJDVSt1ao3EvHc4nHiLTeh8XKtsVkVDV22MInIA1DbRpVYB10ldF7-K_3EoxFB-j2nN4YkfCZyHsFrHnZZnwOV_YsVpMo/s640/IMG_3479.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnjl6bE60zR9StiujBmvuh8pN4NyKzcD5S3pkt-xlK3u_MZujJDVSt1ao3EvHc4nHiLTeh8XKtsVkVDV22MInIA1DbRpVYB10ldF7-K_3EoxFB-j2nN4YkfCZyHsFrHnZZnwOV_YsVpMo/s16000/IMG_3479.JPG" /></a></div><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6MKOyUHtbMRGm4UiClMDsaM1luqXLRB6cwV-qVF8GvBk_gVhyQYJE5x88963ElTlBEFQA8yKXEeI-CDsu_wbTC5gmTHv-5vScftk0JQ84RjuIYBxCr2dVoF2wirtvvxx09pYGIUF5b4g/s640/IMG_3481.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg6MKOyUHtbMRGm4UiClMDsaM1luqXLRB6cwV-qVF8GvBk_gVhyQYJE5x88963ElTlBEFQA8yKXEeI-CDsu_wbTC5gmTHv-5vScftk0JQ84RjuIYBxCr2dVoF2wirtvvxx09pYGIUF5b4g/s16000/IMG_3481.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A bevel was cut to get the curve. Since the foam doesn't want to keep that joint, I used duct tape.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9iRebSO3Kx72XO5s7pO6Qy1v_iDblArNn_3poh2s9hAhyphenhyphenmQ0oQ3JeJVwbfbk1scNoBfDsgJlJyUYjGjW3fFaSzKEjCmN6GvsfO-_yJAqz-yD-CUhnLivRbPETDAXPqnYd7d2jYAAaa2o/s640/IMG_3482.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9iRebSO3Kx72XO5s7pO6Qy1v_iDblArNn_3poh2s9hAhyphenhyphenmQ0oQ3JeJVwbfbk1scNoBfDsgJlJyUYjGjW3fFaSzKEjCmN6GvsfO-_yJAqz-yD-CUhnLivRbPETDAXPqnYd7d2jYAAaa2o/s16000/IMG_3482.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHrqPCb3XgVDHSrSZEkz85OiXZFzsRm7QQw6UweF1q3kri03Akq5Hvdflqo9NP-spmW8TiWjwB7boZ_T2_Rz232_h-f34JWlrmCvLyZr5X88DspWdu4VJKFM071QqAeLYPzwFr4goDuRk/s640/IMG_3483.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHrqPCb3XgVDHSrSZEkz85OiXZFzsRm7QQw6UweF1q3kri03Akq5Hvdflqo9NP-spmW8TiWjwB7boZ_T2_Rz232_h-f34JWlrmCvLyZr5X88DspWdu4VJKFM071QqAeLYPzwFr4goDuRk/s16000/IMG_3483.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNqTuiwc97Zn9BXqPXnjxrigMvt1t-7DO7RQYytERgxLJuVnk1qpfFNkeNfHddpywKkVIx8Ghs8-zT5N25scWBaxnXdO-R0zUz3Q5jvDZreCO9h74bMF9RDKl1NudW0HulBiY6J9EyPI8/s640/IMG_3484.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNqTuiwc97Zn9BXqPXnjxrigMvt1t-7DO7RQYytERgxLJuVnk1qpfFNkeNfHddpywKkVIx8Ghs8-zT5N25scWBaxnXdO-R0zUz3Q5jvDZreCO9h74bMF9RDKl1NudW0HulBiY6J9EyPI8/s16000/IMG_3484.JPG" /></a></div><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCgfSQruvIcwddgY61iVPXuhzma7UY2vIyrIY9H0WldSoRaTu5ugLlBBJMXh5gNMBYGzxBkYqVb8KRghGRHSKTkq0I0DgogbXpw9veJzMHtrsEtIZczOGPITDamiTeJI1dslmReuEHybA/s640/IMG_3495.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjCgfSQruvIcwddgY61iVPXuhzma7UY2vIyrIY9H0WldSoRaTu5ugLlBBJMXh5gNMBYGzxBkYqVb8KRghGRHSKTkq0I0DgogbXpw9veJzMHtrsEtIZczOGPITDamiTeJI1dslmReuEHybA/s16000/IMG_3495.JPG" /></a></b></span><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkNj4bLwmRjiJbzoam8bF-0pRbU66oOt0BCCaMd-eRk47-xT6rqFpzQwEGnCvSKiV3-qEI0n1crlJ7aX7gROn_34Wy1VaNYq_nfFCT3YRotwcPEChX2oc1HyScRJGJqVprLVDBTd_9G0o/s640/IMG_3496.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkNj4bLwmRjiJbzoam8bF-0pRbU66oOt0BCCaMd-eRk47-xT6rqFpzQwEGnCvSKiV3-qEI0n1crlJ7aX7gROn_34Wy1VaNYq_nfFCT3YRotwcPEChX2oc1HyScRJGJqVprLVDBTd_9G0o/s16000/IMG_3496.JPG" /></a></b></span><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH7Y6l_dl2CPHoV2ppAduInSrugpJ6T4tKT4czoMtKUfwoABCf8xdo_0-JNsRhidTHNq6zDCu-1BzUh-ucSNtHaGhy6VjRr8VqhovBpGWyZ_VEUx8SNZ1ByflpkJmCRreirAPP8ceBG44/s640/IMG_3624.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgH7Y6l_dl2CPHoV2ppAduInSrugpJ6T4tKT4czoMtKUfwoABCf8xdo_0-JNsRhidTHNq6zDCu-1BzUh-ucSNtHaGhy6VjRr8VqhovBpGWyZ_VEUx8SNZ1ByflpkJmCRreirAPP8ceBG44/s16000/IMG_3624.JPG" /></a></b></span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxJHw1pGL0LXsLw8PzC2Utex5qPeC5wl3uGy5EV26wkY1W93rprVYdFcbHruxU92amobmoVdrnIGEyNKYAtq9oeEy0sYhr0UAeAUnTAvuyP1-uHMy5nQ851F6A-9goedLcStixtcjQg1Q/s640/IMG_3635.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxJHw1pGL0LXsLw8PzC2Utex5qPeC5wl3uGy5EV26wkY1W93rprVYdFcbHruxU92amobmoVdrnIGEyNKYAtq9oeEy0sYhr0UAeAUnTAvuyP1-uHMy5nQ851F6A-9goedLcStixtcjQg1Q/s16000/IMG_3635.JPG" /></a><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFa_dUOoAWKQ8i0ENmNYQNailPbDPlSoW2le1DQLLP9bRPipvs_TkKsreolsa9ETxkT9ST6V2lUcmXJSbU4AUo0imuvyniRrH_wjBsBtlRxCyFmb7Wz33HkpVrh9KxeTnTn0ZPMkP08e4/s640/IMG_3636.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFa_dUOoAWKQ8i0ENmNYQNailPbDPlSoW2le1DQLLP9bRPipvs_TkKsreolsa9ETxkT9ST6V2lUcmXJSbU4AUo0imuvyniRrH_wjBsBtlRxCyFmb7Wz33HkpVrh9KxeTnTn0ZPMkP08e4/s16000/IMG_3636.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Heat treating the foam will turn it darker and give it a sheen.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjilZc3DTqYeMMZj6IiVmX7X8K9zJ78xYhDsAVT07CBdM4MPLY-6MdcYRXituxvBgIVHx3p4VixRSdu-mnH4WzZj_LAC8aFbYd9otTnrMs4-YfLUus1L8hleDn-3_tZN54sSIJPK0mGAuE/s640/IMG_3637.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjilZc3DTqYeMMZj6IiVmX7X8K9zJ78xYhDsAVT07CBdM4MPLY-6MdcYRXituxvBgIVHx3p4VixRSdu-mnH4WzZj_LAC8aFbYd9otTnrMs4-YfLUus1L8hleDn-3_tZN54sSIJPK0mGAuE/s16000/IMG_3637.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Too much prolonged heat and you can burn the foam.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4peMLv8fAMyvNHLzWWD0ElRW8dbjfY2X0CHZcLc9lPsmtMByjXumDUeF6e-iDcx2D3CmBgDaLm8i-UfyhDhKG4yiVls5y8BdnYML0VmGuPHLDbxmQe0P3gUnfQz2EdZjbqs9Owk84du4/s640/IMG_3638.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4peMLv8fAMyvNHLzWWD0ElRW8dbjfY2X0CHZcLc9lPsmtMByjXumDUeF6e-iDcx2D3CmBgDaLm8i-UfyhDhKG4yiVls5y8BdnYML0VmGuPHLDbxmQe0P3gUnfQz2EdZjbqs9Owk84du4/s16000/IMG_3638.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I labeled all pieces "L" left and "R" right just to keep locations correct.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIrxpnlHbSWKuWhN5k29fJZqbALZee0JXmWfwp4Q80zvYCnVVa5Zp26ZFFRejEtFf6kMHDh8YONHArP-EEWRO02XoUN9rpNTzzmsO3RAAvMMDH8qkRTLf-b1ArjaZNLA-2T4yda6pMw9E/s640/IMG_3639.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIrxpnlHbSWKuWhN5k29fJZqbALZee0JXmWfwp4Q80zvYCnVVa5Zp26ZFFRejEtFf6kMHDh8YONHArP-EEWRO02XoUN9rpNTzzmsO3RAAvMMDH8qkRTLf-b1ArjaZNLA-2T4yda6pMw9E/s16000/IMG_3639.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbrvZ7k1WPSv39r5cJEGr5zLL4ErLOQ5epkCRFzRdJSF6GOQ8vP3keewv-puf-MrgB_XhKP6LQyKFV8az8XCwyovAk3JczOqI_bKwGVZdD4Jn4ZwAkK0t8w7nqSXmh3XanGsGKBDhN4Dk/s640/IMG_3640.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbrvZ7k1WPSv39r5cJEGr5zLL4ErLOQ5epkCRFzRdJSF6GOQ8vP3keewv-puf-MrgB_XhKP6LQyKFV8az8XCwyovAk3JczOqI_bKwGVZdD4Jn4ZwAkK0t8w7nqSXmh3XanGsGKBDhN4Dk/s16000/IMG_3640.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYmIoOorMLDplfWTtxwM4Fy9-_OWNaSfhci_VFdSEsqjIl7IJKqiRPjfnY5kX4GDV-8ngV43lQKCbCL1bQZToS9Pt2m6c2bxuXQm3V9pJdtQvb8ZerVWZ5YU3qQGfjfveocWaUE9RmQ2I/s640/IMG_3788.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYmIoOorMLDplfWTtxwM4Fy9-_OWNaSfhci_VFdSEsqjIl7IJKqiRPjfnY5kX4GDV-8ngV43lQKCbCL1bQZToS9Pt2m6c2bxuXQm3V9pJdtQvb8ZerVWZ5YU3qQGfjfveocWaUE9RmQ2I/s16000/IMG_3788.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0-wfMfsGMh6-jbgsopUhUSRSnlRAsjgDR6ZqVw_scLZBLcPHamvmoT7Psr4g7LRIbs7hMsio0fapzxxbVBY9DA0wWZ2yCDc-SdY6XU5CGRWZY0__1_Gc9SCFdDBxgcuJARE5lQU9RmRQ/s640/IMG_3789.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0-wfMfsGMh6-jbgsopUhUSRSnlRAsjgDR6ZqVw_scLZBLcPHamvmoT7Psr4g7LRIbs7hMsio0fapzxxbVBY9DA0wWZ2yCDc-SdY6XU5CGRWZY0__1_Gc9SCFdDBxgcuJARE5lQU9RmRQ/s16000/IMG_3789.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Leg wrap.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZFpifmlRMRJVNalqY0WUY2azA8EDiR53-O690L7nrEp6T3mqRvBJGiIiItXMAILfK0Wkvkwm6Rc5ia3byQxwLaGWe_5yOLn18KpyCy7rf4nwFZSuf54AoJJPAut0z4cmZmkC9vbiiB0s/s640/IMG_3790.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZFpifmlRMRJVNalqY0WUY2azA8EDiR53-O690L7nrEp6T3mqRvBJGiIiItXMAILfK0Wkvkwm6Rc5ia3byQxwLaGWe_5yOLn18KpyCy7rf4nwFZSuf54AoJJPAut0z4cmZmkC9vbiiB0s/s16000/IMG_3790.JPG" /></a></div><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjR0xGi06JWh336Dyo7MVpG0R8f9hdE6_tS4m2kboSwq7795rFM2ay6OPcm8PE1zcAlzCZeFCd1oNlJD766d-sZ0moffp4T4RjFaPkY5fTtl7HrEpGvmLRS2lmtaTeAQs77Jg-ETjXPGfU/s640/IMG_3835.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjR0xGi06JWh336Dyo7MVpG0R8f9hdE6_tS4m2kboSwq7795rFM2ay6OPcm8PE1zcAlzCZeFCd1oNlJD766d-sZ0moffp4T4RjFaPkY5fTtl7HrEpGvmLRS2lmtaTeAQs77Jg-ETjXPGfU/s16000/IMG_3835.JPG" /></a>Cloth Goods - Flight Suit, Half Mask, </b></span><span face=""arial" , "helvetica" , sans-serif"><b><span face=""arial" , "helvetica" , sans-serif"><b>Torso Wrap, Vest, Cape, </b></span>Gloves</b></span><br />
The flight suit started as coveralls. I cut off front pockets, hammer loop, and sleeve pocket.<p></p><p>I
cut the sleeves and resewed them to look like double sleeves. I added a
lot of white stitching to simulate the prop. There are lines on each
upper arm. I spaced mine .75" with the center at 1.5". There's a diamond
stitch pattern on each elbow. There's an additional strip from the
inside elbow to collarbone outlined with white stitching. That one is 1"
wide.</p><p>I used chalk to sketch out straight lines before sewing them. <br /></p><p>I added stitching on the arms before sewing the sleeves back together. This makes access MUCH easier. <br /></p><p>There's white stitching around the fly and curving from the outside knee to belt buckle.</p><p>The
half mask covers my neck/chin from view. I wear the collar of the
flight suit up, with the half mask on top. It extends half way up the
back of my head, around my ears, and down to my chin. I cut 10" off the
bottom of each pant leg for the half mask. I cut the leg down the seam
and added 2" from the other leg to lengthen it. The half mask has white
stitching on each side of the neck that is spaced 3/4".</p><p>I added a strip to the back outlined in white with velcro.<br /></p><p>The
torso wrap is a muslin material. I had this on hand, but probably used a
few yards. The wrap is double thickness as the material is thin. The
wrap has a center section with horizontal banding on the sides. I used a
template for this, 'trying it on' to make sure it looked right.<br /></p><p>I
created separate sections and sewed them together. I dyed it with tea
just to change the color a bit. If I had time I would have sprayed it
with watered down dark acrylic to make it even darker.<br /></p><p>I added
snap buttons at each top corner with a corresponding snap on the lower
back shoulder of the flight suit for attachment. I used a leather punch
to create the holes for the snaps.<br /></p><p>The chest plate vest is
muslin. I created a paper template to make sure it looked right, using
my chest plate as reference for size. The straps are leather scraps. The
vest was too short after I sewed it together. I used a seam ripper to
cut the straps on the back. Instead of replacing them, I just added an
extension. While there is a seam, the cape will cover it.</p><p>The cape
is a wool blanket. Cosplayers have done it from fleece and the pill of
the fabric in reference photos makes it look like fleece, but I liked
the look and feel of wool better for the cape.<br />At the neck, the right
corner comes straight down from the back over the shoulder with the
other side coming over the left shoulder and across the chest. The cape
is 30"x60". Looking at it in plan, on the long side, the cut curves out
for the piece that comes across the chest. So at the top the cape is 36"
wide with a roughly 12" long curve<br />I sewed that and the wrinkles together. It wouldn't wrinkle 'right' on its own.<br /></p><p>I
cut the neck opening a bit larger so I could slip the cape over my head
easily and to get rid of the excess material at the back of my neck. <br /></p><p>I used scissors to cut the bottom edge, taking out small triangles. Then a rasp to distress the fabric</p><p>The
gloves are the black gauntlet gloves over the yellow gloves. Cut the
black gloves close to the knuckle. I glued velcro onto the back of the
black gloves for the plastic hand guards.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwRp5EfJLnvyciZJsxh-4_A8ivRCD1PeFCY-SCWRAIAd96URkqk85ThCFFoGv16aKxhtuCVM4yY3-34bqNOckMCJOAx1m6VBiI6riX8OpgFDG2A9ya-gTobkMGvkYu2C8QsH3SC0p_bBo/s640/IMG_3460.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwRp5EfJLnvyciZJsxh-4_A8ivRCD1PeFCY-SCWRAIAd96URkqk85ThCFFoGv16aKxhtuCVM4yY3-34bqNOckMCJOAx1m6VBiI6riX8OpgFDG2A9ya-gTobkMGvkYu2C8QsH3SC0p_bBo/s16000/IMG_3460.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I bought coveralls, gloves, and shoes.<br /></td></tr></tbody></table><p>Once the gloves are
done, get black shoe polish and rub it into crevices to give the gloves a
worn look. Start in a spot that doesn't show to get a feel for it. I
focused on the yellow gloves, you won't notice black shoe polish on the
black gloves.<br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaUGt0dcZ4jUkEBvoBFhH_XJBNHA80hD_aF3SC8oXh3KxSxWCrdo6_ss7kOoDwBcNtXTBW8BuoLBz99-jjISBc-MKk-5WG4SDSSjkTIpClCuz0SrOHEDm2F1_eOlf6Ns55rwhMfv10SEw/s640/IMG_3498.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaUGt0dcZ4jUkEBvoBFhH_XJBNHA80hD_aF3SC8oXh3KxSxWCrdo6_ss7kOoDwBcNtXTBW8BuoLBz99-jjISBc-MKk-5WG4SDSSjkTIpClCuz0SrOHEDm2F1_eOlf6Ns55rwhMfv10SEw/s16000/IMG_3498.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A rotary cutter is great for cloth as it allows you to keep it flat which helps<br />when cutting around a template.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitut27pTi5aAcQ2ybQ4Juk5NwypelW5z7PD1cvUptLuPNqVe_H9NqZPpD4riDE55yUHdft0cXssoIFiIHuUrd-nvLAdS9LGntuLAz2scTN0Bwk9SXBbZGVQB0Y1gmgHIgBn68ZTOUf0uA/s640/IMG_3499.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitut27pTi5aAcQ2ybQ4Juk5NwypelW5z7PD1cvUptLuPNqVe_H9NqZPpD4riDE55yUHdft0cXssoIFiIHuUrd-nvLAdS9LGntuLAz2scTN0Bwk9SXBbZGVQB0Y1gmgHIgBn68ZTOUf0uA/s16000/IMG_3499.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Vest.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzxKTcQLZS-pGPd-Hbzlmc1Vos67TC4oneacUc4TYBa8JbFfttu73c9kzJdTKLiz0ijOicc5AyK2w6-DFA2Sl96O0v8KXVvmwzuPKaWWykTsQMPv30vOP4cKAJUEp8-p5FzktcgGwEeCs/s640/IMG_3500.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzxKTcQLZS-pGPd-Hbzlmc1Vos67TC4oneacUc4TYBa8JbFfttu73c9kzJdTKLiz0ijOicc5AyK2w6-DFA2Sl96O0v8KXVvmwzuPKaWWykTsQMPv30vOP4cKAJUEp8-p5FzktcgGwEeCs/s16000/IMG_3500.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmulEyyIznfVz6kMgqdRCUrbR8LUB7F26AxtDi3LXBbYMDMHI8fcq6zlCcHxlFRPqJFxJyntiyPS9dD4ykdeIu-dHYPNaKZbOWyKVqjqItkZ5nz2vF7ADN1MDi4fpUUUGTmZ2vSvKa25M/s640/IMG_3501.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmulEyyIznfVz6kMgqdRCUrbR8LUB7F26AxtDi3LXBbYMDMHI8fcq6zlCcHxlFRPqJFxJyntiyPS9dD4ykdeIu-dHYPNaKZbOWyKVqjqItkZ5nz2vF7ADN1MDi4fpUUUGTmZ2vSvKa25M/s16000/IMG_3501.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtXkCtJK4i8CeEETbyLNV86qGLDfPApM_FaqRxDu7OAXN8RFoC9LChDS9r35VPcB_OMz5rSDYA7QyCBlzXOYSck9BQxAGAiv51ynU_nu_N3mjFVm18hkaDxdFFM8xhHg5NXmhs65rrlEc/s640/IMG_3502.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtXkCtJK4i8CeEETbyLNV86qGLDfPApM_FaqRxDu7OAXN8RFoC9LChDS9r35VPcB_OMz5rSDYA7QyCBlzXOYSck9BQxAGAiv51ynU_nu_N3mjFVm18hkaDxdFFM8xhHg5NXmhs65rrlEc/s16000/IMG_3502.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Torso wrap.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4BsrUSmUdlxkPmt95fXGvFd5xQgCm0zWYH8h1Dk8RY2vXx4iX8X4APkI6fNDWQ4RrriLOonyu_oQk6Budfj03844bVCbEF3Ix92_OxbHd6fZyT7HPC01NEfTA7lh-ws2d4Rj1DdLC62o/s640/IMG_3503.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4BsrUSmUdlxkPmt95fXGvFd5xQgCm0zWYH8h1Dk8RY2vXx4iX8X4APkI6fNDWQ4RrriLOonyu_oQk6Budfj03844bVCbEF3Ix92_OxbHd6fZyT7HPC01NEfTA7lh-ws2d4Rj1DdLC62o/s16000/IMG_3503.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjctXxo5DbjzI02Eaqom5vJDj3CRdA3_1QV-UY1blMCQla6W58K-UtB3BHrWLJZbq4-n7j21n1oZ4TiIsmbxrjWwsnJ3MsLDh5aJ496CXy_imAd2XJPziumQKP710Z-sjjEja5hMQc3as4/s640/IMG_3505.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjctXxo5DbjzI02Eaqom5vJDj3CRdA3_1QV-UY1blMCQla6W58K-UtB3BHrWLJZbq4-n7j21n1oZ4TiIsmbxrjWwsnJ3MsLDh5aJ496CXy_imAd2XJPziumQKP710Z-sjjEja5hMQc3as4/s16000/IMG_3505.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGP-rvfBDZPnjvk7frs4m1ZifXwBQKx1USt65kz3aVg8vQLYxOXxIXyF65M9v-1tNQX4gAQ_Aqnl3A9ZozUT-oHwGcFwKYxDWc2If0FL94oJgoSjYW953nIhqPuPq2uUgrU7yoHkxUqC8/s640/IMG_3506.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgGP-rvfBDZPnjvk7frs4m1ZifXwBQKx1USt65kz3aVg8vQLYxOXxIXyF65M9v-1tNQX4gAQ_Aqnl3A9ZozUT-oHwGcFwKYxDWc2If0FL94oJgoSjYW953nIhqPuPq2uUgrU7yoHkxUqC8/s16000/IMG_3506.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I cut the sleeves of the coverall to simulate the double sleeve effect.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnPLV3yKjLWTBtWvE4xnD8o6muxw5SPCSMCqc3iPOwFfrCV-QZeM7xoHgvco3SOuA-iMYJT6cwun0MKz_HNSauVMqhZmHKBFAUcx2-1wMsU5NXXzLRry6Ky2Kx8z1tp-9eFUFnbjH2Pgg/s640/IMG_3507.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnPLV3yKjLWTBtWvE4xnD8o6muxw5SPCSMCqc3iPOwFfrCV-QZeM7xoHgvco3SOuA-iMYJT6cwun0MKz_HNSauVMqhZmHKBFAUcx2-1wMsU5NXXzLRry6Ky2Kx8z1tp-9eFUFnbjH2Pgg/s16000/IMG_3507.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHOu2n_4OxvVrEUzqq0P1MI7731R72Fj_mwPDeLjzfVwwZY5b039FEitR6GSWYTllhUDsyageWSS8dz75a1WEey38GdfNYK-fA6xLaCS-gEGzawEpW-5Ls6RR8M9ENfqP2kZaCgLi0FUc/s640/IMG_3508.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHOu2n_4OxvVrEUzqq0P1MI7731R72Fj_mwPDeLjzfVwwZY5b039FEitR6GSWYTllhUDsyageWSS8dz75a1WEey38GdfNYK-fA6xLaCS-gEGzawEpW-5Ls6RR8M9ENfqP2kZaCgLi0FUc/s16000/IMG_3508.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Chalk lines act as guides to keep stitching straight.<br /></td></tr></tbody></table><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRHYHMTI6xB81Bd1L6jsu1V_3GzoonAJyT4FtqcdJPma6pGCQm_Shyphenhyphen9-QVwbzUBarpRYq-cmK8A4vji90WU9ZnMuvxqOlVdaGrl-FWFtIrtiFmbWTL_Eg-evm4tDqL49UTyQ1vqyRYdNY/s640/IMG_3511.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRHYHMTI6xB81Bd1L6jsu1V_3GzoonAJyT4FtqcdJPma6pGCQm_Shyphenhyphen9-QVwbzUBarpRYq-cmK8A4vji90WU9ZnMuvxqOlVdaGrl-FWFtIrtiFmbWTL_Eg-evm4tDqL49UTyQ1vqyRYdNY/s16000/IMG_3511.JPG" /></a></p><p><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6UtGLfuMTHF5UswQAE25FX0E6n4YxX2F5T5MENWdekEGDcTXLJ_Pm5NtLo50eYEWRjz7RC3md_COcFKKzU81qmJVPi0vuKsmyYmieoXBZH6okEcOZFivAzyMtHSz7WyyR4ATE7Pl8kfA/s640/IMG_3622.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6UtGLfuMTHF5UswQAE25FX0E6n4YxX2F5T5MENWdekEGDcTXLJ_Pm5NtLo50eYEWRjz7RC3md_COcFKKzU81qmJVPi0vuKsmyYmieoXBZH6okEcOZFivAzyMtHSz7WyyR4ATE7Pl8kfA/s16000/IMG_3622.JPG" /></a></b></span></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOtr0eFZr4Hzd8Lp-_gyXVcHJ4eWnLZYHMoFBsVYmdMF-L20dKNNvB4uPjQZ25kg2_NJyNr-1JZlYxJMCn3tM1W5DQLrv3ejwbQhPPP4YOtUtv5pfJhci8EjTHShSIL-Ff3i3BTzMQdj0/s640/IMG_3509.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOtr0eFZr4Hzd8Lp-_gyXVcHJ4eWnLZYHMoFBsVYmdMF-L20dKNNvB4uPjQZ25kg2_NJyNr-1JZlYxJMCn3tM1W5DQLrv3ejwbQhPPP4YOtUtv5pfJhci8EjTHShSIL-Ff3i3BTzMQdj0/s16000/IMG_3509.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Cut the black gloves close to the knuckle.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQbFrLcTa7__PbWXeiHb1Ulb__WDNXVyJ39rXLjXbcycR9778rCEOqJC7UDWS6KXTAzPQ0FqOR16C0JyTnMm55YrU9o6IW2VTuqApe4xp0vCvNMQYsTILuVI2aFFEOWpuBeFzGXAY6E1M/s640/IMG_3632.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQbFrLcTa7__PbWXeiHb1Ulb__WDNXVyJ39rXLjXbcycR9778rCEOqJC7UDWS6KXTAzPQ0FqOR16C0JyTnMm55YrU9o6IW2VTuqApe4xp0vCvNMQYsTILuVI2aFFEOWpuBeFzGXAY6E1M/s16000/IMG_3632.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I cut part of the pant leg to make the half mask. A velcro strip runs along the back.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ9Hfgn5xGcST-EcufXqwOcfljJ12NeeGYWYPG6eqikCE7nSnXAqpP6-Ejt1AXg-LAQgmDgL6wWAjOnD3hdZX7eZNNRkORbbpY0yW9mH6Or7-IQ9uSQXzeRsKaQRxCZyIMNbjnb6Yr_8k/s640/IMG_3634.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQ9Hfgn5xGcST-EcufXqwOcfljJ12NeeGYWYPG6eqikCE7nSnXAqpP6-Ejt1AXg-LAQgmDgL6wWAjOnD3hdZX7eZNNRkORbbpY0yW9mH6Or7-IQ9uSQXzeRsKaQRxCZyIMNbjnb6Yr_8k/s16000/IMG_3634.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The half mask wraps around my chin and the back of my head so that my neck is not visible.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVOPacaWAdsjQNWJGx6vo8wg7H-sWUovVv7PdUsf_vIYARyhGRTAkfLHeZ2IEZTYNZ2P6h1i5SL1_MykmazaGjJaHWkYFDmGv76kUJyMCjeMVPxvvy8T6BLCPJ387LajqB193IiUZirHM/s640/IMG_3510.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVOPacaWAdsjQNWJGx6vo8wg7H-sWUovVv7PdUsf_vIYARyhGRTAkfLHeZ2IEZTYNZ2P6h1i5SL1_MykmazaGjJaHWkYFDmGv76kUJyMCjeMVPxvvy8T6BLCPJ387LajqB193IiUZirHM/s16000/IMG_3510.JPG" /></a></div><span face=""arial" , "helvetica" , sans-serif"><b></b></span><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6oN3K-PKcsufXlWDXJe289FGb0G3JBdOSPUXvcxH-breD-L8j4vK1yubTrdurbYmPsctnCZN1IolgnBa863Bdu9F47ZSvu6ijZjoPRDMZTPn4N8oT9hPxNQtFzVnFtT0X0paF0KJjLtk/s640/IMG_3633.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6oN3K-PKcsufXlWDXJe289FGb0G3JBdOSPUXvcxH-breD-L8j4vK1yubTrdurbYmPsctnCZN1IolgnBa863Bdu9F47ZSvu6ijZjoPRDMZTPn4N8oT9hPxNQtFzVnFtT0X0paF0KJjLtk/s16000/IMG_3633.JPG" /></a></b></span><span face=""arial" , "helvetica" , sans-serif"><b></b></span><span face=""arial" , "helvetica" , sans-serif"><b><br /></b></span><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwBtO-ryvCGugST5OgzV3jrdOmQA_2RPS25AStDlprfSTG8is1lfIe9LR5bBphmjCv6WhKqShvh0VSHDN_FdjxoljuGBtAEvA023_OeWE8pCQqgFcdh_7Sa_dF7sjRdbiFK4AkIBguqfE/s640/IMG_3922.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwBtO-ryvCGugST5OgzV3jrdOmQA_2RPS25AStDlprfSTG8is1lfIe9LR5bBphmjCv6WhKqShvh0VSHDN_FdjxoljuGBtAEvA023_OeWE8pCQqgFcdh_7Sa_dF7sjRdbiFK4AkIBguqfE/s16000/IMG_3922.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The bottom edge of the cape.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3IZW1igdtLOacWXOWXJRz0Q8kTx5UWEYLwt8nz_nkbdMZofbBSjA6FqpqgzqPkvdN21kSzPK59tYsYpABnc_VdCY_xBggJiVw5NH4w5EoOvbTJbI245RA5SP1NkitESc9OpC3_KwpCfs/s640/IMG_3923.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3IZW1igdtLOacWXOWXJRz0Q8kTx5UWEYLwt8nz_nkbdMZofbBSjA6FqpqgzqPkvdN21kSzPK59tYsYpABnc_VdCY_xBggJiVw5NH4w5EoOvbTJbI245RA5SP1NkitESc9OpC3_KwpCfs/s16000/IMG_3923.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Cut with scissors for a ragged appearance.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP4nAWVFgyaHf8r_QLvy9GpnH4Xyx_lkvx1B1MKsM-Q0PgV7Ac2RCyO_v0JKOBtCPavRXE7LjjkSZAHhoPQBk8gKjTlyBUTnqNLTKgDQA5gu0CZKgII7_i_THgBp4-Iom1S3Wf_H-DuLg/s640/IMG_3924.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiP4nAWVFgyaHf8r_QLvy9GpnH4Xyx_lkvx1B1MKsM-Q0PgV7Ac2RCyO_v0JKOBtCPavRXE7LjjkSZAHhoPQBk8gKjTlyBUTnqNLTKgDQA5gu0CZKgII7_i_THgBp4-Iom1S3Wf_H-DuLg/s16000/IMG_3924.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A rasp gives it the worn look.<br /></td></tr></tbody></table><span face=""arial" , "helvetica" , sans-serif"><b>Leather - Belt & Bandolier</b></span><br />I
used real leather for the belt and bandolier. You could use craft foam,
but leather looks better and is more durable. I ordered scraps with no
guarantee on color, but I got a nice brown color that works. The
alternative would be to use shoe polish to get the color closer to
accurate.<br /><p>The belt and bandolier are double thickness except at the grenades. Both are 2" wide, stitched along the outside edge.</p><p>The belt has a ~1.5" circular leather feature with a bottom. I couldn't figure out a good way to attach the bottom and didn't.<br /></p><p>As with all the pieces, these started as paper templates. <br /></p><p>For
the (2) belt grenades I used 1/2" conduit with foam pressed into each
end. It's rudimentary but worked for my time table. From 10' away it
looks great. The grenade loops are 1.625" long with the loops attached
on the belt spaced at .75". At the circular feature and grenades, the
belt is single thickness.</p><p>The belt also has a 4"x4"x1" leather
pouch. It's the same size as the foam pouch on the leg wrap. I cut floor
mat foam to size as a base and wrapped the leather around it. My
leather is to thin to hold shape, but that thinness makes it easy to
work. The pouch is one big piece of leather adhered with contact cement.
I made a belt loop that runs through the pouch. The rivet in the pouch
is 3/16".<br /></p><p>The belt buckle is a piece of scrap aluminum I had.
I cut it to size with a hack saw, then filed the edges true and flat. I
drilled out the notches on the drill press with a 3/16" bit. The rivets
are 1/8".</p><p>I tried (and tried) to sand the paint off the buckle
but it seems it was powder coated and well adhered. I left it as is, but
the edges are raw aluminum, giving it a worn look.<br /></p><p>The back
of the buckle has an aluminum angle (1"x.5") as the clasp. I cut an
opening into the angle with a drill and file. The other end of the belt
loops into the angle and fastens with velcro. With the angle on the back
basically centered, the buckle wants to flip out. The angle/loop needs
to be at the outside edge. I didn't have an angle the correct size.
Using a 2x2 angle with one side cut down to .5" would fix that issue.<br /></p><p>The
bandolier is double thickness leather except at the grenades. There are
(6) loops and (5) grenades. The sizing/spacing is the same as the belt
as I used conduit here too. There is a square piece of leather with an
opening above the grenades.</p><p>I did not include the rifle clip. I was going to create the base clip/snap, but forgot.<br /></p><p>The
bottom of the bandolier attaches to the belt with velcro, piece on the
inside of the belt and velcro on the end of the bandolier. The other end
of the bandolier attaches to the back of the flight suit with velcro on
my shoulder blade.</p><p>The grenades are 1/2" conduit. I have (13)
total: five on the bandolier, two on the belt, six on the shin. I cut
them 2.75" long with a hack saw. I then filed the edges flat/true and
deburred the conduit. I pressed the conduit into scrap foam and cut the
imprint left. I applied contact cement inside the tube and pushed the
foam into the end. Don't let the contact cement dry and do not put it on
the foam. If you do, you won't be able to get it into the tube and
adjust it. The foam stays in place well with just a friction fit and
hopefully with the contact cement it won't move at all.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6zg9IUQNbwyAVQ_v6BNE19tg4XuHSz0gDZ1iRtOttYYWnHyw3IWA6Feo-20EJEP2EnbK8-y8ZB6HQsep9RBBsSQtoIFS8DoMiE2Rc0QEyBhjhlId77zZtjW8jtFJNp0khThGmwlvokAI/s640/IMG_3796.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6zg9IUQNbwyAVQ_v6BNE19tg4XuHSz0gDZ1iRtOttYYWnHyw3IWA6Feo-20EJEP2EnbK8-y8ZB6HQsep9RBBsSQtoIFS8DoMiE2Rc0QEyBhjhlId77zZtjW8jtFJNp0khThGmwlvokAI/s16000/IMG_3796.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXbPQHlVIU6nKd6RJkIbPp547BY0nfAccDH1Le_qq149cq01TnUci84LL-qpGNUoRN20ADIDgAgCvHeqfXk21pivieJjY2OC8mX_c3D5uhcpLhBVsbmom-PGm-QjzEV9kBf1Ii1mB0SO0/s640/IMG_3797.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXbPQHlVIU6nKd6RJkIbPp547BY0nfAccDH1Le_qq149cq01TnUci84LL-qpGNUoRN20ADIDgAgCvHeqfXk21pivieJjY2OC8mX_c3D5uhcpLhBVsbmom-PGm-QjzEV9kBf1Ii1mB0SO0/s16000/IMG_3797.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The "grenades" are all 1/2" conduit<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikxjiV5SNl7i2fRAfOl_fU1u5WeIscOsfvbZ0QXJrdTgxXrLCkF0HBQhjOcTMYl1APRV2keJO5GwpoDEE6XRyUwb1_ew5Hhku8FUSLJSfCboGT8CWDiwKphyphenhyphenwBzSTV5wnyfYKygf0tqCU/s640/IMG_3798.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikxjiV5SNl7i2fRAfOl_fU1u5WeIscOsfvbZ0QXJrdTgxXrLCkF0HBQhjOcTMYl1APRV2keJO5GwpoDEE6XRyUwb1_ew5Hhku8FUSLJSfCboGT8CWDiwKphyphenhyphenwBzSTV5wnyfYKygf0tqCU/s16000/IMG_3798.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMKxVhS6RXIN_-b93R_mx4YCoSfgqqDxam0XE1l9gR-ru9GgY6Dr9HM4CQamMhHFDNFPNlsbJqfgUEucFRJ16fgzk5Kd3OxSvDf0uUoJ64dBhasbzPnw6QOiWxQu47ztIi24jlWmh9IQA/s640/IMG_3799.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMKxVhS6RXIN_-b93R_mx4YCoSfgqqDxam0XE1l9gR-ru9GgY6Dr9HM4CQamMhHFDNFPNlsbJqfgUEucFRJ16fgzk5Kd3OxSvDf0uUoJ64dBhasbzPnw6QOiWxQu47ztIi24jlWmh9IQA/s16000/IMG_3799.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZr5mc5_MQwU_ruubpD7S3HO7B5V0yZazXPdp33mdG1_gCwJbFFT0by5vfJM7AiLQx_GnQcrgLyO7cLzlw_p8qZXbBadcglOWxrxVVqz3rf01Nxnw1-KWwOlCvcAnGDg55tf6JGpLoEy0/s640/IMG_3812.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZr5mc5_MQwU_ruubpD7S3HO7B5V0yZazXPdp33mdG1_gCwJbFFT0by5vfJM7AiLQx_GnQcrgLyO7cLzlw_p8qZXbBadcglOWxrxVVqz3rf01Nxnw1-KWwOlCvcAnGDg55tf6JGpLoEy0/s16000/IMG_3812.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The belt buckle started as scrap aluminum.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqAnIvtCNMCBcLivsGAyD-pRDsfgPJAByQQarwSxb-uUfGKZcvb1D4qEOSsYc3yWvfcWfjuk0nTvKEMPQ4Nh9y2zFnjXXxIakTSrvPm90CTUXbqAdpplEl42QfNhA0CPRQvhCYyKKiYDU/s640/IMG_3813.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqAnIvtCNMCBcLivsGAyD-pRDsfgPJAByQQarwSxb-uUfGKZcvb1D4qEOSsYc3yWvfcWfjuk0nTvKEMPQ4Nh9y2zFnjXXxIakTSrvPm90CTUXbqAdpplEl42QfNhA0CPRQvhCYyKKiYDU/s16000/IMG_3813.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Cut to shape.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMfsj0xt_4HN2TLlCW7pSB_26YW5V4eDAewZ51Sv_5726u2omagsey4sW3XNlDGg9KmgxT5_3O_5J-ClapERbCRWR0j1Ohlj1_OhPQq0Bhq07HdENUFpl5r6Qa123hehTY9RSKPmsOiro/s640/IMG_3814.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMfsj0xt_4HN2TLlCW7pSB_26YW5V4eDAewZ51Sv_5726u2omagsey4sW3XNlDGg9KmgxT5_3O_5J-ClapERbCRWR0j1Ohlj1_OhPQq0Bhq07HdENUFpl5r6Qa123hehTY9RSKPmsOiro/s16000/IMG_3814.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Edges filed to be straight and true.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3Rj1i_gZjx1aSRy26q9cHeZoD45-396d1TkgyFJ5HLlFqsxioM6-mriuVHaavFdGnyMgqiHTfrkAowkHsPjS1a87ydI_tZi-bsrkljP-eu390CSb6J-LeIYFuvDnMdpRAKNXOIk03f2M/s640/IMG_3815.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3Rj1i_gZjx1aSRy26q9cHeZoD45-396d1TkgyFJ5HLlFqsxioM6-mriuVHaavFdGnyMgqiHTfrkAowkHsPjS1a87ydI_tZi-bsrkljP-eu390CSb6J-LeIYFuvDnMdpRAKNXOIk03f2M/s16000/IMG_3815.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A punch marks where to drill.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjosm-ghBKafR4T_3VsIu28iVc7oD2req7vYY6IC2OAHIXnIu_Nm9PcHyKFnmvwer53HmaQCg2CItnYQm57zdVjfWk4waWQWJkpcrnldJ0Mj9a22h2NBEQ_xkxkzNXr2O-DpSh1GJhT8Nw/s640/IMG_3816.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjosm-ghBKafR4T_3VsIu28iVc7oD2req7vYY6IC2OAHIXnIu_Nm9PcHyKFnmvwer53HmaQCg2CItnYQm57zdVjfWk4waWQWJkpcrnldJ0Mj9a22h2NBEQ_xkxkzNXr2O-DpSh1GJhT8Nw/s16000/IMG_3816.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Drilling the openings.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzjbasbCBBNcPY-7SGMJP1pQOLGhh4G6pdn6bjG90mX-HyJJB4HpsAz7zGxTmy92CWYZ-TralQbnFqaIv762-EDRHwSMFiS8HuSDVepNw54_E-3bkcEA7vCIWGdHftu-r1Y4vRj8wrSCE/s640/IMG_3817.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzjbasbCBBNcPY-7SGMJP1pQOLGhh4G6pdn6bjG90mX-HyJJB4HpsAz7zGxTmy92CWYZ-TralQbnFqaIv762-EDRHwSMFiS8HuSDVepNw54_E-3bkcEA7vCIWGdHftu-r1Y4vRj8wrSCE/s16000/IMG_3817.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Cutting what the drill left behind, which was then filed straight.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm0fhRsaWWfvvYOQOY28iG8ZSA6jp3ezVYhg4BBr_opCfMPckqC1KXlLLeq_QkK2uCiLbzD2nH5uC2vegx0PBd_le0tVWHFsh2T7rP-KjQew5c9AjKIZqmkuydoztkfUq_u8M4XchvGB8/s640/IMG_3819.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjm0fhRsaWWfvvYOQOY28iG8ZSA6jp3ezVYhg4BBr_opCfMPckqC1KXlLLeq_QkK2uCiLbzD2nH5uC2vegx0PBd_le0tVWHFsh2T7rP-KjQew5c9AjKIZqmkuydoztkfUq_u8M4XchvGB8/s16000/IMG_3819.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Almost complete buckle. It was powder coated, so I gave up trying to remove the paint.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisk-C6bQQ5-U6DBvHnV6WJuWzEGe42XVrHbpkshslhTlJ1kX_ERTYWlIjoD7fIKJN_YQd9twtX9cX0kSvKF0f12biz2Hh1b1IfxySYJLPJRxpoCz8w9Sie65jeHEeMJytC1PHbJjJmZzQ/s640/IMG_3820.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisk-C6bQQ5-U6DBvHnV6WJuWzEGe42XVrHbpkshslhTlJ1kX_ERTYWlIjoD7fIKJN_YQd9twtX9cX0kSvKF0f12biz2Hh1b1IfxySYJLPJRxpoCz8w9Sie65jeHEeMJytC1PHbJjJmZzQ/s16000/IMG_3820.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK7DBEwDJvWXyuFooSZGcXotAOgBFWADzrmpLCVhsUUMZxtKUGQHBxnowgizKlQ-6bu-Oi2cyjS45Sa9vyAG5ANz5OZF66YfMuGylyWZe6_vRoaGty9MX7Pz3RTpdjOa-eLlbcwrN_XoE/s640/IMG_3823.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK7DBEwDJvWXyuFooSZGcXotAOgBFWADzrmpLCVhsUUMZxtKUGQHBxnowgizKlQ-6bu-Oi2cyjS45Sa9vyAG5ANz5OZF66YfMuGylyWZe6_vRoaGty9MX7Pz3RTpdjOa-eLlbcwrN_XoE/s16000/IMG_3823.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8XvonExhf1fxnkA-6ryT3okc8X_jxxuqSSaIa5csqN_fmjMNYJpMDGOnWfKkOf8TnnYU6ofCkbNTEihjhFaMm__HzfLIfMuO_9m-xv1NqAN7rLmvS4votgh6a9aDOnFabpxe6INv_M04/s640/IMG_3824.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg8XvonExhf1fxnkA-6ryT3okc8X_jxxuqSSaIa5csqN_fmjMNYJpMDGOnWfKkOf8TnnYU6ofCkbNTEihjhFaMm__HzfLIfMuO_9m-xv1NqAN7rLmvS4votgh6a9aDOnFabpxe6INv_M04/s16000/IMG_3824.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhyphenhyphenq89tBo2IPCUp8G7x9nUsc10_ohO1mzhnm2ItOY_jJsbi0LSMH_jG8x3NKi2JkTrkITFxKWlbejcHfEGIUgkv4nqITohxNTau1b4PtmjF-LuJkXkGozqfyqcMeBmyMQBAD2kk7LTpRY/s640/IMG_3825.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhyphenhyphenq89tBo2IPCUp8G7x9nUsc10_ohO1mzhnm2ItOY_jJsbi0LSMH_jG8x3NKi2JkTrkITFxKWlbejcHfEGIUgkv4nqITohxNTau1b4PtmjF-LuJkXkGozqfyqcMeBmyMQBAD2kk7LTpRY/s16000/IMG_3825.JPG" /></a></div><p><b>Plastic - Hand Guards & Shin Guard</b><br />The
hand guards are .04 styrene with .04 styrene trim and a triangle. The
outside edges curve slightly around the hand. After finishing these,
they look a bit too large. To get the bend, I heated the plastic and
clamped it between two pieces of plywood. Don't heat the plastic to much
as you don't want it to deform. You want it just warm enough to bend.
It may take a few tries to get the bend correct.<br /></p><p>The shin
guard is a single piece of styrene with styrene banding around the top.
The triangular piece is styrene base with foam triangles. I don't like
how the triangles came out, but it's a small detail that will likely be
ignored.</p><p>I scored the front to mimic the grooves and that was a
mistake. I know that if you score styrene you can just snap it. I should
have added strips of styrene on top of the base to create the effect.
It was too late in production to fix this correctly.</p><p>I heated the plastic to curve it around my leg. It needs to be an oval shape. <br /></p><p>A
craft foam wrap at the bottom with velcro on each end and a craft foam
grenade holder at the top secure it. I added velcro on the styrene too
as the plastic just doesn't like holding the curve.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgewLBbkoc5FwKfvVXmMhuhU1r90SGSuTtdantQWXD7l92ioVVSy_QqKFRbBZCtcyD7ldgIgmYVvhfmR6cRcT1Y_5_2CJ3i5y6Mt92xVgRYkaSmdIOmQGYgsrps5Xv5WwSwkhurLBa0jWA/s640/IMG_3494.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgewLBbkoc5FwKfvVXmMhuhU1r90SGSuTtdantQWXD7l92ioVVSy_QqKFRbBZCtcyD7ldgIgmYVvhfmR6cRcT1Y_5_2CJ3i5y6Mt92xVgRYkaSmdIOmQGYgsrps5Xv5WwSwkhurLBa0jWA/s16000/IMG_3494.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Hand guards are .04 plastic.<br /></td></tr></tbody></table> <b><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzM5-lLaPET8sfVP0BFevk81HSUIdjBkTnpV0s7i4zJrB_Kw3Q6Bf_4FRrlzsFLnQM1PfSXsXWBJtTYD-KcVlRFQL19H3Gyi-gFtl1UwKA8YPVQDuIVDZBsQWjweKFbjIY2dOdn1dcQOM/s640/IMG_3611.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzM5-lLaPET8sfVP0BFevk81HSUIdjBkTnpV0s7i4zJrB_Kw3Q6Bf_4FRrlzsFLnQM1PfSXsXWBJtTYD-KcVlRFQL19H3Gyi-gFtl1UwKA8YPVQDuIVDZBsQWjweKFbjIY2dOdn1dcQOM/s16000/IMG_3611.JPG" /></a></b></b><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvJJKvZR2-qrEL-5A6sOCpM598Xg-mXGqUec3sTmj6rfjAfXdUmYj7QRwNRvKrwkEUMKXz5fVLKZmh7Fwf-DekNI8n0Me3DbuhmDTCOjiQ33dZsroaqYHRAmmS8SNjuXDeFRMH4UjwcJo/s640/IMG_3791.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvJJKvZR2-qrEL-5A6sOCpM598Xg-mXGqUec3sTmj6rfjAfXdUmYj7QRwNRvKrwkEUMKXz5fVLKZmh7Fwf-DekNI8n0Me3DbuhmDTCOjiQ33dZsroaqYHRAmmS8SNjuXDeFRMH4UjwcJo/s16000/IMG_3791.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Leg armor is a 'for sale' sign which can be a quick substitute for .04 plastic sheet.<br /></td></tr></tbody></table><p><b></b><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgph0QoZw3huc_RnsYfyZDuV2SpJrl-AZrj6FE6JzWKzQ9plSwmBcc3l7BNdvm8vND3x6qPGEboJtVOnMNWW9mf-9I7Bd6YVOWtLgK1iHnhlY_mS7mTR7OMEPuT6Rw6wefn-Yzq2danwcA/s640/IMG_3792.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgph0QoZw3huc_RnsYfyZDuV2SpJrl-AZrj6FE6JzWKzQ9plSwmBcc3l7BNdvm8vND3x6qPGEboJtVOnMNWW9mf-9I7Bd6YVOWtLgK1iHnhlY_mS7mTR7OMEPuT6Rw6wefn-Yzq2danwcA/s16000/IMG_3792.JPG" /></a>Rigging</b><br />
Lots of velcro was used to attach the armor. While I used adhesive
backed, that's only because I bought the wrong thing. When attaching
velcro to the suit, I sewed it on. With adhesive backed, that gets
adhesive on the needle so you need to clean the needle frequently.<br />When
attaching velcro to foam, I applied contact cement to the foam. The
velcro didn't need any since it was adhesive backed. If it didn't have
the backing, just apply contact cement to the back of the velcro.<br /></p><p>The
chest plate has (4) pieces of velcro, one for each corner. Shoulder and
thigh armor have two strips each running horizontally at the top and
bottom.</p><p>Each shoulder pauldron has a vertical strip. The hip
plates have a horizontal strip attached to the torso wrap and a single
square towards the bottom of the plate on the suit as the belt made the
plates want to flip out.<br /></p><p>I used painters tape to match up the
location of the velcro on the armor with the location on the flight
suit. Sometimes that doesn't work as I added a second strip to the left
shoulder pauldron as it attached a bit too far forward.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilnoSbH9CDcGunksKHsnqLLUhgiw-TQM-8GxE8hdXhMeWN4IoRLwxie06eXftWcIyrh7KAeJYP6lhLGoRXg58m34uHC93l7BBv_poabK59XvKxVlMHKAB9cG6zuMC8cUZq0KbBSrOMVzE/s640/IMG_3837.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilnoSbH9CDcGunksKHsnqLLUhgiw-TQM-8GxE8hdXhMeWN4IoRLwxie06eXftWcIyrh7KAeJYP6lhLGoRXg58m34uHC93l7BBv_poabK59XvKxVlMHKAB9cG6zuMC8cUZq0KbBSrOMVzE/s16000/IMG_3837.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Contact cement glues velcro to the foam.<br /></td></tr></tbody></table><p><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTk9uXak2BIqzDI5l9tGjh4TF84Jxh1JOn5GsOnoFQV8YO9Ymq_fKu5BkqwGBC2-0Ykf3Fuj1d615qhvyTDIIsMpqpiZF1tBTYBzO0jGkxVMYbX4VXxyMlDhEQTS_6EQUBp14kJA_x9l0/s640/IMG_3879.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTk9uXak2BIqzDI5l9tGjh4TF84Jxh1JOn5GsOnoFQV8YO9Ymq_fKu5BkqwGBC2-0Ykf3Fuj1d615qhvyTDIIsMpqpiZF1tBTYBzO0jGkxVMYbX4VXxyMlDhEQTS_6EQUBp14kJA_x9l0/s16000/IMG_3879.JPG" /></a>Finish & Paint</b><br />All
foam gets heat treated before paint. A heat gun pointed at the foam for
a few seconds will do it. The foam will become a bit darker and develop
a sheen. This seals the foam so it absorbs less paint.</p><p>Once the
foam is sealed spray the foam with Plasti-dip. It's a durable, flexible
base for the color. There are other options like thinning PVA glue
(white Elmer's glue). I've never tried it.</p><p>I used acrylic caulk for the seams of the helmet and shoulders. Thinning it with water and using your finger works well.<br /></p><p>For
the tan pieces, I sprayed a base of tan, lightly misted with gray, and
then misted again with tan if needed. A single solid color looks like a
toy. A mottled appearance looks real.<br /></p><p>For the brown pieces, I
sprayed them brown, misted with gray and in some cases red-brown, then
repeated colors until I got the right shade. For the chest plate, and
left shoulder I added in bronze. I made the chest plate more bronze, and
the gauntlets more red.<br /></p><p>Mottling the colors makes the armor
look more realistic. It also gives all the armor a similar shade of
color even if the tone differs.</p><p>I didn't mottle the 'leather' leg wrap. Leather doesn't look mottled. <br /></p><p>Check
the paint cans to determine drying time. You should paint outside in a
well ventilated area and even then wear a respirator.</p><p>Leave all items in the shade to dry, direct sunlight can cause the paint to bubble.</p><p>I
left the helmet in the shade, but as the sun rose it was in direct
sunlight, causing the Plasti-dip to bubble. Being a rubber coating a
bubble in Plasti-dip is more difficult to fix than regular paint as it
won't just sand or cut out. I cut it the best I could and used Half-time
to smooth out the mess.<br /></p><p>Weathering is the final stage of
painting. It gives the armor a used and worn look. Think about how
things would wear. While the bottom edge of the cape doesn't look dirty,
it should be. I didn't paint it because I ran out of time.<br /></p><p>Armor
pieces may have a primer between the 'metal' and paint finish. When I
have more time I like to paint pieces with Plasti-dip for a durable
base, then silver for metal, then white or gray for primer, then the
final color. I didn't have time here. Instead I dry brushed silver onto
the edges.<br /></p><p>Cloth goods will be dirtier under armpits, at
knees, and bottom of pant legs. If I had time I would have sprayed the
chest plate vest and torso wrap with a watered down dark acrylic.<br /></p><p>I've
used water color, acrylic, and oil paints to weather; mostly what I
have on hand. Water color is better if you want to try to clean the item
up later. Oil is a lot less forgiving, once you wipe it on, it will
wipe off but tint the final color. It's great depending on the type of
dirt you want to imitate. I stick to acrylic. It thins and cleans up
easily with water. </p><p>The entire helmet needs a dark wash, it's much
too bright. Acrylic will just wipe away. I did a test on the back with
oil. It dulls the silver with a nice dark tint. While leaving crevices
darker. I wiped the oil paint on as thin as I could then wiped it off
with a clean rag. Change rags often. You can use acetone to cut through
the oil paint, but be careful as it will also cut through your base
coat. I used some acetone on the ear pieces as they are lighter. The oil
paint wipe darkens the helmet and makes it look a lot better.<br /></p><p>With
all the pieces, brown and/or black will get wiped into cracks and
crevices and gently wiped away. This leaves the paint in corners and
lends to a dirty and used look.</p><p>The flight suit got sprayed with
watered down white and brown. It looks much too new. I only did one
spray and didn't notice a difference, with more time I'd like to spray
it again. I may test wiping thinned paint directly on it to dull the
black.<br /></p><p>For the armor, I used black oil paint around blaster
impacts. Then I painted the impacts with silver. I also dry brushed
edges with silver. Dip the brush in paint and then blot it. You want
very little paint, just enough to highlight the edges. I used black
paint in crevices and corners. Weathering gives pieces depth. The low
points are darker, the high points are brighter.</p><p>I wiped shades of brown and black on and off to give a dirty appearance or streaks.<br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDnI5Ge9NMGWkH4jqjAFKX2HoJbVP0pdltMDLRla_erXLSStzsD7dyB3Q6Dhku-KG5ykzq3H48DKdxkg5eYu-NPcg-fXL4bCY7BcVmwW1yFg8nikM8KNf2py-WnwUQLtcnHvIJHENUSOY/s640/IMG_3794.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDnI5Ge9NMGWkH4jqjAFKX2HoJbVP0pdltMDLRla_erXLSStzsD7dyB3Q6Dhku-KG5ykzq3H48DKdxkg5eYu-NPcg-fXL4bCY7BcVmwW1yFg8nikM8KNf2py-WnwUQLtcnHvIJHENUSOY/s16000/IMG_3794.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Acrylic caulk fills any gaps.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQfXPAD4mPqCfYi6HEfKLo_LHONEu2upFsR3uC3UAkWMhYOKvnOxaPms6tcKGxIf7wDV8sZ3cZmBq5eFPHiCL-mSRz2dRgCbFZwANfEaxXqBkNitOYOiJifHUfgKbN9qMPRneNSRIZcF4/s640/IMG_3795.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQfXPAD4mPqCfYi6HEfKLo_LHONEu2upFsR3uC3UAkWMhYOKvnOxaPms6tcKGxIf7wDV8sZ3cZmBq5eFPHiCL-mSRz2dRgCbFZwANfEaxXqBkNitOYOiJifHUfgKbN9qMPRneNSRIZcF4/s16000/IMG_3795.JPG" /></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMLHaTKJW89qwxnyC2FUZu8fS_L4Tblmey36PgTrlesRF0nAK-CsDLsAvclEFHDwpr1uRThbg3hSfcGBaDNT78rWLjYhaJf7Y4EtOf5mCREuphDoaJpO6od6Wb8_Zbk5HYz3TGx8LrTF8/s640/IMG_4156.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMLHaTKJW89qwxnyC2FUZu8fS_L4Tblmey36PgTrlesRF0nAK-CsDLsAvclEFHDwpr1uRThbg3hSfcGBaDNT78rWLjYhaJf7Y4EtOf5mCREuphDoaJpO6od6Wb8_Zbk5HYz3TGx8LrTF8/s16000/IMG_4156.JPG" /></a><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJtkV0tL4OSVxJfwHx5ojdAzFCR8ClZ66vuhCvqeRT04tRguBADlyuk5FCdfl2W8p1FemR1Yb5xdISPYsC0_RzXpbq3MtYi2-UThpcv4SA85TDuAq5vZTprt4nHmjNjLzYwEFfo-5ooyo/s640/IMG_3801.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJtkV0tL4OSVxJfwHx5ojdAzFCR8ClZ66vuhCvqeRT04tRguBADlyuk5FCdfl2W8p1FemR1Yb5xdISPYsC0_RzXpbq3MtYi2-UThpcv4SA85TDuAq5vZTprt4nHmjNjLzYwEFfo-5ooyo/s16000/IMG_3801.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Plasti-dip base coat.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3rv-9DKw_fbLkY8GtbHE6bTpdxZnxJNi9wKujTqjWJl-eqWAXa0U1UasNIftkYTC06caDEmxiUixMH4_NUm0y5T63dUCEBPmLgAp1mRWZo_sS8WxfQVXdCOFDfTVHh2VSAmMjzpsTkAI/s640/IMG_3803.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3rv-9DKw_fbLkY8GtbHE6bTpdxZnxJNi9wKujTqjWJl-eqWAXa0U1UasNIftkYTC06caDEmxiUixMH4_NUm0y5T63dUCEBPmLgAp1mRWZo_sS8WxfQVXdCOFDfTVHh2VSAmMjzpsTkAI/s16000/IMG_3803.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmUCGAmvjZSQth24KSq_X0fDJMNhaVK25dYEmU_EFo59JVQ9wgjWn_AjRiG6B3_zB2CS5iW4-uq_UWL0vWneBF8PyEpS-C2eDHhaPmzrhMI02AfYg0BoIeA2CgTRjoMvuBUQqa2jouyDw/s640/IMG_3804.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmUCGAmvjZSQth24KSq_X0fDJMNhaVK25dYEmU_EFo59JVQ9wgjWn_AjRiG6B3_zB2CS5iW4-uq_UWL0vWneBF8PyEpS-C2eDHhaPmzrhMI02AfYg0BoIeA2CgTRjoMvuBUQqa2jouyDw/s16000/IMG_3804.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Since the helmet should have a very smooth finish, I used Half time filler.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQOcONMAOYT6yJ7QCrd6IjLwIIfnEV_Dwga2FPZ63VdqOgn04H3wXVBlMiruaWPqAYuzTucTq-34fZyuStRZlsqnpxErdGewh6lzu63MSKqpiVt_nJHg5auWr9iELPIfrELcX-iGO7LgM/s640/IMG_3805.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQOcONMAOYT6yJ7QCrd6IjLwIIfnEV_Dwga2FPZ63VdqOgn04H3wXVBlMiruaWPqAYuzTucTq-34fZyuStRZlsqnpxErdGewh6lzu63MSKqpiVt_nJHg5auWr9iELPIfrELcX-iGO7LgM/s16000/IMG_3805.JPG" /></a></div><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm-aFmCfrk1OEoMXCqizgGMmwRdj33a3CRNpJFy4jvFuntZbFNjKpfWLcIOl4ji6wKq79IqJXDTifJ-fSUwejPhQrUc70Uc4QRuQSJs1SOg7V9vXZn7FRmcYM9g_QpGg84rF98MqL85UY/s640/IMG_3821.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgm-aFmCfrk1OEoMXCqizgGMmwRdj33a3CRNpJFy4jvFuntZbFNjKpfWLcIOl4ji6wKq79IqJXDTifJ-fSUwejPhQrUc70Uc4QRuQSJs1SOg7V9vXZn7FRmcYM9g_QpGg84rF98MqL85UY/s16000/IMG_3821.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Left it in the shade, but the sun rose and got the helmet, separating this joint and leaving a few bubbles.<br />This required another round of Half time filler.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXN-mxAft0JhF34L7Spd55Hn93R1z0VcMDG8CcafwOLbs8tBN4RjlaAep4-P-Jiy6KTHcArBxuaDUrAHSl-iGWH7XgV7rvOaMqOFKV4ZuZnEcpzaJz7rWlZzPkPUi-IG_EC-vmyapbUpU/s640/IMG_3822.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXN-mxAft0JhF34L7Spd55Hn93R1z0VcMDG8CcafwOLbs8tBN4RjlaAep4-P-Jiy6KTHcArBxuaDUrAHSl-iGWH7XgV7rvOaMqOFKV4ZuZnEcpzaJz7rWlZzPkPUi-IG_EC-vmyapbUpU/s16000/IMG_3822.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7PeWgoacbNXYJaFYvCoUoGVxQ96OMWgS-XSBA617BOV3HmRQLxi2ZhjHCy0uBtSNJHe-ccIPy4KUd7qSC915os9euYjqPzWq4JDMEAI0P_d21uNJpAYyd9SoLnOuhuDACSe99AzLdZdM/s640/IMG_3830.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg7PeWgoacbNXYJaFYvCoUoGVxQ96OMWgS-XSBA617BOV3HmRQLxi2ZhjHCy0uBtSNJHe-ccIPy4KUd7qSC915os9euYjqPzWq4JDMEAI0P_d21uNJpAYyd9SoLnOuhuDACSe99AzLdZdM/s16000/IMG_3830.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Silver paint. You can't get chrome in a spray can, at least not without spending a fair amount.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiOZzsnQkQChEEjR63FwACButvxoOUVwR9oobPL7w7I3IS6pW7dMPm4ydoKHRUyUsfeDS-wEnYcFEuYXogNMwj7IGuk66f58QaWkTclsQjteBQGxyRG3Lk6YKJdS3rsxegVT0skulXdU0/s640/IMG_3832.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiOZzsnQkQChEEjR63FwACButvxoOUVwR9oobPL7w7I3IS6pW7dMPm4ydoKHRUyUsfeDS-wEnYcFEuYXogNMwj7IGuk66f58QaWkTclsQjteBQGxyRG3Lk6YKJdS3rsxegVT0skulXdU0/s16000/IMG_3832.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNgPMO-VyNj-cKGN2MvMI564U7q9JgkiDD1jx4K8HrvxlKil9IFH-PxFEYDKdGH047-IEXRrsyFkzyl1eH3bu6qu5k36ag6tdMEPRjjAGceKCx_17quj0Jri7bJfbxNklTHu-xnD29Yks/s640/IMG_3833.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNgPMO-VyNj-cKGN2MvMI564U7q9JgkiDD1jx4K8HrvxlKil9IFH-PxFEYDKdGH047-IEXRrsyFkzyl1eH3bu6qu5k36ag6tdMEPRjjAGceKCx_17quj0Jri7bJfbxNklTHu-xnD29Yks/s16000/IMG_3833.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhndyw3z-8dim6z3GTbT6KR09LNptbFfX-EM380d30Vp4KCFY8Yw4j2YxFQfn7OKiWVWlv0bvxrwHM0VRb0tdanMnAbBVYh03GjA-i6_8QO1J30Ip_Z1tIvDQz6GL_kNj1rxn3SRgnkjyQ/s640/IMG_3834.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhndyw3z-8dim6z3GTbT6KR09LNptbFfX-EM380d30Vp4KCFY8Yw4j2YxFQfn7OKiWVWlv0bvxrwHM0VRb0tdanMnAbBVYh03GjA-i6_8QO1J30Ip_Z1tIvDQz6GL_kNj1rxn3SRgnkjyQ/s16000/IMG_3834.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPTqI77e23WiBFWJm3hx-6VkcjZUTtLJHZn9Hwn6ZDM4529UN9onThGyzCQfLngxeImr5WdiaGZ3brpHFa26qAprSThAWvakUnWfFLdqKaqd7fyyoMDRX1oHGGhcpO-hhNg1jb_vJKs74/s640/IMG_3925.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPTqI77e23WiBFWJm3hx-6VkcjZUTtLJHZn9Hwn6ZDM4529UN9onThGyzCQfLngxeImr5WdiaGZ3brpHFa26qAprSThAWvakUnWfFLdqKaqd7fyyoMDRX1oHGGhcpO-hhNg1jb_vJKs74/s16000/IMG_3925.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLpAnKArC-53RPIVjUWbfUo7F8aAzfkgCrOZBRh9J3J9at5q_1Kxd_0JoP4yy8-r3HuyVnsAD4Axc_z1fWM1OxGmTdlMevY-_lbqUS9cck-WxkmlGp5rdcltPdmFwfga446ihifIlbix8/s640/IMG_3944.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLpAnKArC-53RPIVjUWbfUo7F8aAzfkgCrOZBRh9J3J9at5q_1Kxd_0JoP4yy8-r3HuyVnsAD4Axc_z1fWM1OxGmTdlMevY-_lbqUS9cck-WxkmlGp5rdcltPdmFwfga446ihifIlbix8/s16000/IMG_3944.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7dO5kfX1q7RjJ6-BlOgHXVcYCeL2HW_OvRvO_o81OUoWnth2guAtmdebW_q1VAxhN7E0HWnwZGINuMTn7wJZZBI-eNz1g2wFslYy7hJuIIjqGcJS7qpRUH-YhgaMI18vef2UXPmVEd0c/s640/IMG_3964.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7dO5kfX1q7RjJ6-BlOgHXVcYCeL2HW_OvRvO_o81OUoWnth2guAtmdebW_q1VAxhN7E0HWnwZGINuMTn7wJZZBI-eNz1g2wFslYy7hJuIIjqGcJS7qpRUH-YhgaMI18vef2UXPmVEd0c/s16000/IMG_3964.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTamNGO2womCYPWBgGlVKKz9M_ahyphenhyphen8igI5MTLcKrT2medJ8NyRMcQFfYgHqmprqSUBaYtjnXCIYDA4QvENTV6LXwbo64ae9OoiXGp4sjKAnSWWkNVVJr_O1a5mFBCDATk9Zi9JtYihLdA/s640/IMG_3973.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTamNGO2womCYPWBgGlVKKz9M_ahyphenhyphen8igI5MTLcKrT2medJ8NyRMcQFfYgHqmprqSUBaYtjnXCIYDA4QvENTV6LXwbo64ae9OoiXGp4sjKAnSWWkNVVJr_O1a5mFBCDATk9Zi9JtYihLdA/s16000/IMG_3973.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIc5LkyWaP5XKGMhMJNFMUoM4hmkLQQTTAdOjOFxD63IqT42-SZP09AzPSNaoQcFubNP9Lp3wTKZdZkigZahUlHCmV3K1Bp-kbRFYT2CVrTG_biamLuZTPZ0iT-4uBbxbByRgEDKZx_mU/s640/IMG_3806.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIc5LkyWaP5XKGMhMJNFMUoM4hmkLQQTTAdOjOFxD63IqT42-SZP09AzPSNaoQcFubNP9Lp3wTKZdZkigZahUlHCmV3K1Bp-kbRFYT2CVrTG_biamLuZTPZ0iT-4uBbxbByRgEDKZx_mU/s16000/IMG_3806.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdH0hu8Ktjr5sVGAMfZ7yTBsvWTrTtimjoioaWmpBh-ZQkNreZs1reHSNSn54X7j9a-kHG3AQv_hIrFcJY2eVWa14PrxOfxSjreKqtV0nVxdXDu7mvArVqycVwVd9pw7-KDqW1E_JVIpU/s640/IMG_3807.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdH0hu8Ktjr5sVGAMfZ7yTBsvWTrTtimjoioaWmpBh-ZQkNreZs1reHSNSn54X7j9a-kHG3AQv_hIrFcJY2eVWa14PrxOfxSjreKqtV0nVxdXDu7mvArVqycVwVd9pw7-KDqW1E_JVIpU/s16000/IMG_3807.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Plasti-dip base.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgATtIRkxZKrxhIYjJeL0J4PWDapJgQNkoOG057p7s5VH0GSzXKZNuJiLaIF42dit1OtdF9WhGB1Mq3bhSMfk8ZRx9W6BLQqtJOHX2Hm58pykteeOf048zd7PQgZ27nK4SatDp4RnrhaK8/s640/IMG_3808.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgATtIRkxZKrxhIYjJeL0J4PWDapJgQNkoOG057p7s5VH0GSzXKZNuJiLaIF42dit1OtdF9WhGB1Mq3bhSMfk8ZRx9W6BLQqtJOHX2Hm58pykteeOf048zd7PQgZ27nK4SatDp4RnrhaK8/s16000/IMG_3808.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Red color coat followed immediately by a misting of brown.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaJfErl46TQQ9YaYPFrRdnXAdMylgp_jFc9I1BfObzMhnreeOKSHpnB2ub0dWlqUTilhnRet0dWiSnRzvqsSNBpdsaqnK1sM-so1jhPhMwV3Qzmnq4xKPNTPmrlsX89FC94c9aDZNCc1g/s640/IMG_3809.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaJfErl46TQQ9YaYPFrRdnXAdMylgp_jFc9I1BfObzMhnreeOKSHpnB2ub0dWlqUTilhnRet0dWiSnRzvqsSNBpdsaqnK1sM-so1jhPhMwV3Qzmnq4xKPNTPmrlsX89FC94c9aDZNCc1g/s16000/IMG_3809.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A few sprays of gray, not all over, just in a couple spots.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0f8C73lxWQOSR6QqEGoibpHWxyvw-BTwisEjNhzjZACyjlwt3P7j3jv4xHxdLcCoh5tzc5JuwZ0JvaxRAu7jPgfl-rRye0oooDing6bO3yfGbw9QlL-y2UtS5LARUTl4_IZJS_Et1XWg/s640/IMG_3810.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0f8C73lxWQOSR6QqEGoibpHWxyvw-BTwisEjNhzjZACyjlwt3P7j3jv4xHxdLcCoh5tzc5JuwZ0JvaxRAu7jPgfl-rRye0oooDing6bO3yfGbw9QlL-y2UtS5LARUTl4_IZJS_Et1XWg/s16000/IMG_3810.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A light coat of bronze.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8hCzB1m0Di-p1o1UIjGcVvaBYSDqG8zOvPycs6UCeT0XaAFTCZM1IR4C_hhNPlDFZtPAyjAiR654CeaCPLTFgoH7jrofxTJYGG0KtOlYyiKMcNlheETFlMIJWH7MBk46IuUCMHwKfbvc/s640/IMG_3811.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8hCzB1m0Di-p1o1UIjGcVvaBYSDqG8zOvPycs6UCeT0XaAFTCZM1IR4C_hhNPlDFZtPAyjAiR654CeaCPLTFgoH7jrofxTJYGG0KtOlYyiKMcNlheETFlMIJWH7MBk46IuUCMHwKfbvc/s16000/IMG_3811.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9S5Y1sVxF6Egt2p5ZxZLWt4IOLNe-q377pxTjJA4wx4lOyTMmZCCwuAgGNXck0QrL_l1DYtg8uiXC_jvmBbfXyvsiraErjFxXebfG_V8AD75MSEyMixyg0tZ7pSpQiaMbiRMmI4WVu1o/s640/IMG_3838.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj9S5Y1sVxF6Egt2p5ZxZLWt4IOLNe-q377pxTjJA4wx4lOyTMmZCCwuAgGNXck0QrL_l1DYtg8uiXC_jvmBbfXyvsiraErjFxXebfG_V8AD75MSEyMixyg0tZ7pSpQiaMbiRMmI4WVu1o/s16000/IMG_3838.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJvVf3EiF-nUB0zdzjFi1wQQfXYGywKPElkBgEI0n5BbbTil-yeC7C8NMEXRS3rBNP9PfNKMlhmh14JdUuhzE9kDjkw-ZsRQiH9HXLQRz1nFTjgVNB1O7jKQLkdpuXdaWRXeWK3G0fRdw/s640/IMG_3877.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="481" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJvVf3EiF-nUB0zdzjFi1wQQfXYGywKPElkBgEI0n5BbbTil-yeC7C8NMEXRS3rBNP9PfNKMlhmh14JdUuhzE9kDjkw-ZsRQiH9HXLQRz1nFTjgVNB1O7jKQLkdpuXdaWRXeWK3G0fRdw/s16000/IMG_3877.JPG" /></a></div><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih0X1TJp-Xbz3VlFVYDYY2w__oXbno2FeRMhKQ54Fl7TtvD5in9WIX3DiiQOVc1gRzkx5SM864rbYvxfhDnAe_VK6dRLSCmPwQpE6p0CBF9EMsnefR2AgZWZH-koWNZCVxozbHBAZ38aQ/s640/IMG_3976.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih0X1TJp-Xbz3VlFVYDYY2w__oXbno2FeRMhKQ54Fl7TtvD5in9WIX3DiiQOVc1gRzkx5SM864rbYvxfhDnAe_VK6dRLSCmPwQpE6p0CBF9EMsnefR2AgZWZH-koWNZCVxozbHBAZ38aQ/s16000/IMG_3976.JPG" /></a></div><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHOYII6ADsPwuqKZfsoSBtJ5GDngwwIwq0-WdyzAgeB-_Kqb56gWddda1rrXn4wEzjwUt7Vxc0rAVPCUu6z7Vsb1C-pFo1nTIQLd0OYZi5IjStthyJX8KbMWWwt8E2fMXw64bKAtgnOqU/s640/IMG_3921.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHOYII6ADsPwuqKZfsoSBtJ5GDngwwIwq0-WdyzAgeB-_Kqb56gWddda1rrXn4wEzjwUt7Vxc0rAVPCUu6z7Vsb1C-pFo1nTIQLd0OYZi5IjStthyJX8KbMWWwt8E2fMXw64bKAtgnOqU/s16000/IMG_3921.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The visor cut to fit the helmet.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWXdbYw_G-GVpfUbr7AFOfxfmSDKxo1MaOXx9ybcv2JmNM6YnueevvNMYFtLkGefAmtkqUd1h-e1eujpvbRJAC76mQ5PjzTKT_4WhpGk3zQajy611yddowtDp7vvHhhslkOM_EozjD2js/s640/IMG_3977.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWXdbYw_G-GVpfUbr7AFOfxfmSDKxo1MaOXx9ybcv2JmNM6YnueevvNMYFtLkGefAmtkqUd1h-e1eujpvbRJAC76mQ5PjzTKT_4WhpGk3zQajy611yddowtDp7vvHhhslkOM_EozjD2js/s16000/IMG_3977.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLNr1M_kziGv67UtakKMwM9Cw_sSu6i-vDTRh6cboNov3JJppmeRruJRcnjc4XstlBYw5AuWW3FB8D7kIrxcY6G0_1OtV39AC1VaCRItnaMPXSw-hsY861f5p7Lx5OXFjibCqPOm2-iPY/s640/IMG_3978.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLNr1M_kziGv67UtakKMwM9Cw_sSu6i-vDTRh6cboNov3JJppmeRruJRcnjc4XstlBYw5AuWW3FB8D7kIrxcY6G0_1OtV39AC1VaCRItnaMPXSw-hsY861f5p7Lx5OXFjibCqPOm2-iPY/s16000/IMG_3978.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgChZJE5aLP48biQffHijOSsE7myX1NoC4Ru2k44o85z7LI9ev6fxkrTKrSmM0Y-PTl54QUT386grPmrPUCP8thpBD0GGo4uELQNTBukyy9Kpl_pDrKD5YTKn11n5bTmIMgNiYo_y9-t8M/s640/IMG_3979.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgChZJE5aLP48biQffHijOSsE7myX1NoC4Ru2k44o85z7LI9ev6fxkrTKrSmM0Y-PTl54QUT386grPmrPUCP8thpBD0GGo4uELQNTBukyy9Kpl_pDrKD5YTKn11n5bTmIMgNiYo_y9-t8M/s16000/IMG_3979.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A black oil wash. Acrylic will wipe off completely, oil doesn't. Since I wanted to knock down<br />the silver, oil was the way to go.<br /></td></tr></tbody></table><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4Izz-XcDQkz0LHohPdu16r8omDL7ewWWzmByspd6R1j63y_vqrFIxqsrs8MTvLolvklFxf04-NRyP2Y21mXv9Mfr6fPK2kwNfeCYrwD1JHij_fHXnWYX7PNZeFW8f9cC-n-wAvJOejEI/s640/IMG_3980.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4Izz-XcDQkz0LHohPdu16r8omDL7ewWWzmByspd6R1j63y_vqrFIxqsrs8MTvLolvklFxf04-NRyP2Y21mXv9Mfr6fPK2kwNfeCYrwD1JHij_fHXnWYX7PNZeFW8f9cC-n-wAvJOejEI/s16000/IMG_3980.JPG" /></a></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjhjbeTPI66cDCjzUP5af8wJLWZzS7X1duDrrNnP1INruv4a_9VDnUCA9YV2etz-lsz49qfWm1dWTDrulS3_VZZkuzbhjp7GlygqGoHvvkDN3XPcKtSL4Hv3uMYvAgNfQ3CMFXv3KOLak/s640/IMG_3975.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjhjbeTPI66cDCjzUP5af8wJLWZzS7X1duDrrNnP1INruv4a_9VDnUCA9YV2etz-lsz49qfWm1dWTDrulS3_VZZkuzbhjp7GlygqGoHvvkDN3XPcKtSL4Hv3uMYvAgNfQ3CMFXv3KOLak/s16000/IMG_3975.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The base color is brown, misting of gray, and coat of bronze.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcceCnzpxbwq7JVN2qZN40Vyye2ijjeDXKQge__ydvKjSfD9oLplPVa5zaCfUD8C2xwsLsbfvN4sG6VoPJc979e8Q8Hb40xKGWoszc0OSs6lrL4jM5kOxO9g5c9tR1bC0xsrZlFkP_u_k/s640/IMG_3982.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcceCnzpxbwq7JVN2qZN40Vyye2ijjeDXKQge__ydvKjSfD9oLplPVa5zaCfUD8C2xwsLsbfvN4sG6VoPJc979e8Q8Hb40xKGWoszc0OSs6lrL4jM5kOxO9g5c9tR1bC0xsrZlFkP_u_k/s16000/IMG_3982.JPG" /></a></div><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOvOudjVoGEr43uzwxr1sKkz4cjdUam5SzwdJLof8MsJZ118_oazTqCy8Kv7HZAO6vC-0FVzJDvwd5wRD485TV61BZlSi5dzV5Jsk9pl0ilq4ZTiLupMg9P3V-R9Wj6dlsBrSn4tE2QMQ/s640/IMG_3983.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOvOudjVoGEr43uzwxr1sKkz4cjdUam5SzwdJLof8MsJZ118_oazTqCy8Kv7HZAO6vC-0FVzJDvwd5wRD485TV61BZlSi5dzV5Jsk9pl0ilq4ZTiLupMg9P3V-R9Wj6dlsBrSn4tE2QMQ/s16000/IMG_3983.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The silver is acrylic. The black burn marks are oil. Oil gives a slightly dirtier look.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_JrTRftXgt6m0LQRpeavu4sM5P4YZPoBRfVJx8mj5ZpInUKGAje8zharno6-kG6dW24-pufSKyVXLxqjNQrE_zTMmdejX1ndJWMpqyT8DwHaQvCS9st4Qik1uKrCuw1SGCjibLyffpqk/s640/IMG_E3991.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_JrTRftXgt6m0LQRpeavu4sM5P4YZPoBRfVJx8mj5ZpInUKGAje8zharno6-kG6dW24-pufSKyVXLxqjNQrE_zTMmdejX1ndJWMpqyT8DwHaQvCS9st4Qik1uKrCuw1SGCjibLyffpqk/s16000/IMG_E3991.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Acrylic was used for a streaks/scuffs. That way I can removed them competely and start over if I don't like them.<br /></td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSOCoquanixOkek-1WkYOhwYACWBkMpusKbOoTBlgGGCcj_AtrfYzY89pqY9zWKdxjmjrVDwwPRg5Fa5Fnunj4DaNY0I34L0PY1x5zyJVb8DRBu9YPVTxwq5pRgvgqczcHuSF6Xx5qr2Y/s640/IMG_3984.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSOCoquanixOkek-1WkYOhwYACWBkMpusKbOoTBlgGGCcj_AtrfYzY89pqY9zWKdxjmjrVDwwPRg5Fa5Fnunj4DaNY0I34L0PY1x5zyJVb8DRBu9YPVTxwq5pRgvgqczcHuSF6Xx5qr2Y/s16000/IMG_3984.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The pock marks are painted with silver acrylic.<br /></td></tr></tbody></table><b></b><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIYkOGdUBS69FYfhFMsXCLlyj8XNC481aoy81D3B2zAcbMqavb0Nq9u-Vx3w7nhxhQoDNIQDGWZSlnZJt63aGs8ce2HhhpKNmIXvZgsulV-42yXi-kutYf9CNeOyqn2pSRJ8Igw193Uck/s640/IMG_3991.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIYkOGdUBS69FYfhFMsXCLlyj8XNC481aoy81D3B2zAcbMqavb0Nq9u-Vx3w7nhxhQoDNIQDGWZSlnZJt63aGs8ce2HhhpKNmIXvZgsulV-42yXi-kutYf9CNeOyqn2pSRJ8Igw193Uck/s16000/IMG_3991.JPG" /></a></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK8w-y8ifwwt_nl8hDE-K8siynOVjR8BvFOifSmeF10bYQJipsnEJr6a-LAWBY0AySisQZLvQPSH-mHBe1Ht0rOah5ns8TPy9xqqoeHI48x_NrnmsJyVK-nfGDu-75OzYulkHJmr3A9Hg/s640/IMG_3985.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK8w-y8ifwwt_nl8hDE-K8siynOVjR8BvFOifSmeF10bYQJipsnEJr6a-LAWBY0AySisQZLvQPSH-mHBe1Ht0rOah5ns8TPy9xqqoeHI48x_NrnmsJyVK-nfGDu-75OzYulkHJmr3A9Hg/s16000/IMG_3985.JPG" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The leg wrap had a very plastic look to it as I did a base coat of only brown, no misting.<br />I used a darker acrylic to highlight the bottom side of the wrinkles.<br /></td></tr></tbody></table><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiivS8UsOF9H1UscMwhLp5eHdt8Xa0zNS73c-kH22HediVM-8E7HxGg2MP6hEj4tsMs-xeRdFVxcNfB5n3VR_Uo5LIxVxYQJPR1v87DtNbhrtjK5uZV47kXFvBhvSanrevjATtNbSqAstw/s640/IMG_3986.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiivS8UsOF9H1UscMwhLp5eHdt8Xa0zNS73c-kH22HediVM-8E7HxGg2MP6hEj4tsMs-xeRdFVxcNfB5n3VR_Uo5LIxVxYQJPR1v87DtNbhrtjK5uZV47kXFvBhvSanrevjATtNbSqAstw/s16000/IMG_3986.JPG" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitJss0jM19DGQ7vqdElul2Wu6oF2A1Y7Qm8wk7g3oonuES2LsgWkhC2ykbheVVf5Ozqdb-n-Ylni9Gw-0XMCw1BuBiI2e_4A84iIpLUHukUhe8ZGHe1i8nI0YeZD3450vBHHIhtLsQ6_s/s640/IMG_3987.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitJss0jM19DGQ7vqdElul2Wu6oF2A1Y7Qm8wk7g3oonuES2LsgWkhC2ykbheVVf5Ozqdb-n-Ylni9Gw-0XMCw1BuBiI2e_4A84iIpLUHukUhe8ZGHe1i8nI0YeZD3450vBHHIhtLsQ6_s/s16000/IMG_3987.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSopcrIWbUcfUnwem1kGu4Mu2mUSAJu0HGAkRbkvjGKvp52R0E9dXR4nf_B7OEU1Btz9XgeZc5cS_NutxaQY-A3V7hhoiYQlLayPtM4SUR3Eo40HGCqwEAi-GlkoAzoJHiHIVNvfqc4C0/s640/IMG_3988.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSopcrIWbUcfUnwem1kGu4Mu2mUSAJu0HGAkRbkvjGKvp52R0E9dXR4nf_B7OEU1Btz9XgeZc5cS_NutxaQY-A3V7hhoiYQlLayPtM4SUR3Eo40HGCqwEAi-GlkoAzoJHiHIVNvfqc4C0/s16000/IMG_3988.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNMggfFnR_sjN1L2b_O3gOO4sD6_PVJcL0YGu8NIA0fmoa-BXQrSRsY7SXBSg4ckiCNlLZgbs8lufoVL0YDn9RfjH8jGN9r-bJOO8vbLelOCZwGQLGL3Bn1pg0lme6zCgJKQmvHW66wsg/s640/IMG_3989.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNMggfFnR_sjN1L2b_O3gOO4sD6_PVJcL0YGu8NIA0fmoa-BXQrSRsY7SXBSg4ckiCNlLZgbs8lufoVL0YDn9RfjH8jGN9r-bJOO8vbLelOCZwGQLGL3Bn1pg0lme6zCgJKQmvHW66wsg/s16000/IMG_3989.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1jL72GZ5cpYi2LZK6XW-RH8e5kbi9mat1arwurxTggdFbNcv9suVfbOXkEEvKnZUTf25X7Vw59Sce79QVq-ikR4twV9M20SpAYM7kjQpdtAnbwQt646F7xZAWLuMmBMbj8U5K50_41m0/s640/IMG_3990.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1jL72GZ5cpYi2LZK6XW-RH8e5kbi9mat1arwurxTggdFbNcv9suVfbOXkEEvKnZUTf25X7Vw59Sce79QVq-ikR4twV9M20SpAYM7kjQpdtAnbwQt646F7xZAWLuMmBMbj8U5K50_41m0/s16000/IMG_3990.JPG" /></a></div><br /><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxUPw8FTchWIrEtzX0uhI6WIr5S_Sh3SZ159aCfKUvGhfSfFgEPx3Ghz_y8SshsCGkrWv9MHVfipPOn34hd9Qg-gT6UItSWrh8miX_drSYIMTnwjsy-kgp_rM0NoUoEkwpFhD0bvw7yOc/s640/IMG_3992.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxUPw8FTchWIrEtzX0uhI6WIr5S_Sh3SZ159aCfKUvGhfSfFgEPx3Ghz_y8SshsCGkrWv9MHVfipPOn34hd9Qg-gT6UItSWrh8miX_drSYIMTnwjsy-kgp_rM0NoUoEkwpFhD0bvw7yOc/s16000/IMG_3992.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVHIOV8urQRc-apM4jh7qeOtzsaBUXrk6bwLdGAa1I39nutUeI7bN9aCcILcTarQLeE7EVWAH3-PJKeoQE9YH5LZnlwo3AiyYPnmbilbLmdsOELpJ2Y-g5lc7BmfpENS2RqLkoWDwZUsQ/s640/IMG_3993.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVHIOV8urQRc-apM4jh7qeOtzsaBUXrk6bwLdGAa1I39nutUeI7bN9aCcILcTarQLeE7EVWAH3-PJKeoQE9YH5LZnlwo3AiyYPnmbilbLmdsOELpJ2Y-g5lc7BmfpENS2RqLkoWDwZUsQ/s16000/IMG_3993.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEGseN5vSDPXk2o-KrVsbW0eDauPI6_g0JY-z1HCUex1DjaH-2nNq-ZwuL9pmT1MlL9sjONkHsqamI-uqi_tSACWLVHdqMjEfu1EHJz_SLMnZlwk0Q8Kei-CYk91wCctOPCV_uAm0LR0c/s640/IMG_3994.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEGseN5vSDPXk2o-KrVsbW0eDauPI6_g0JY-z1HCUex1DjaH-2nNq-ZwuL9pmT1MlL9sjONkHsqamI-uqi_tSACWLVHdqMjEfu1EHJz_SLMnZlwk0Q8Kei-CYk91wCctOPCV_uAm0LR0c/s16000/IMG_3994.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjURoJ3NzAw5-T8gEjR6cf7956VEe357P3OguV4GIiXFf1pkJm05M1dFIEqrL_QpRMF-pJAwvvCju-uXbBTYU6wFs19B6GokqSY_RmaOliRxMwpPt6Q6CkKlr9zmvUs9h0qOW8SbmAHyMA/s640/IMG_3995.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjURoJ3NzAw5-T8gEjR6cf7956VEe357P3OguV4GIiXFf1pkJm05M1dFIEqrL_QpRMF-pJAwvvCju-uXbBTYU6wFs19B6GokqSY_RmaOliRxMwpPt6Q6CkKlr9zmvUs9h0qOW8SbmAHyMA/s16000/IMG_3995.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-BRDkhG8d4dySsMcZ0L6R3A-HVfWx-p1lIgEBR7WK8wVOWI5FBk6sVDYR6ePNCNlnxVOo2DJmtqax-mPeXNPLDaX9TSfiXoko4D_Jg61Hm9qYVqbUa4CU-HzkvAfaS2S5rhFmoCHlB3I/s640/IMG_3996.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-BRDkhG8d4dySsMcZ0L6R3A-HVfWx-p1lIgEBR7WK8wVOWI5FBk6sVDYR6ePNCNlnxVOo2DJmtqax-mPeXNPLDaX9TSfiXoko4D_Jg61Hm9qYVqbUa4CU-HzkvAfaS2S5rhFmoCHlB3I/s16000/IMG_3996.JPG" /></a></div><b>Unbuilt Items</b><br />I
knew I would never have time to build the rifle or blaster. Those are
projects on their own. That and many places don't like props that look
like weapons.<p>I wanted to build the vibra knife that's stuck in
Mando's right boot. I also wanted to create the boot spats to better
match the actual suit, but that didn't happen either.</p><p>A few more
days of paint and weathering would have been nice. The one thing I
really wanted done was the old/worn nature of the suit. One spray down
of acrylic didn't do the trick. <br /></p><p><b>Conclusion</b><br />The
first test fit was a fun moment. Finally all these pieces look like
something. It's a fun costume that many recognize. I knew with building
the helmet out of foam it would never be a display piece. It came out
slightly better than I expected. I had time constraints, and I'm not
sure how I could create it like I want without a 3d printer, a CNC, some
combination thereof, or creating a tooling foam buck for molding.</p><p>It's
not a difficult costume to wear, though you lose your lower periphery
vision in the helmet. The plastic shin armor scrapes on the shoe. A
piece of craft foam on the back bottom edge may quiet that down. </p><p>It's a fun costume. It puts a smile on my face every time I try it on.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEqyv05BwaO8W-2-qSa6MDMFjClYmw979usmM3zyy3i5jRPwZDp7LyT2uSMF2ZTAaYWyJwg5p9io1mcp6hoZEYWFytxgXw_k6IJFkk6CehOZOHCiPTLkASvPRoiTVUKMu9cAMSd3WfPTg/s640/IMG_4086.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEqyv05BwaO8W-2-qSa6MDMFjClYmw979usmM3zyy3i5jRPwZDp7LyT2uSMF2ZTAaYWyJwg5p9io1mcp6hoZEYWFytxgXw_k6IJFkk6CehOZOHCiPTLkASvPRoiTVUKMu9cAMSd3WfPTg/s16000/IMG_4086.JPG" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCfzRD4hnAsY4NgUPEMxtu0yKeq7S-rnCO-WUADJbdxxsdSQdEcThtUtAzrN0d1uRakHqInjhOhXTNdzS6RSIhRWQc1x83kn8DlqmdFpeFBQO6kD-aFddWrNx8QhXZxBCapKqdTOWIlvU/s640/IMG_4088.JPG" style="margin-left: 1em; 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text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiANO4hDahrC3QnrD8kSErUJl_nnZFI8ArStI7tEUwuXmRMTXMjMSMkJlvakHCPHaO67dCGW417f1uUTyMBU4Ye0IC8jAXfaa_KEDlWoUuPtGMojpDd0sPLQ5nAWQLBbnusCG2uNDWbMtI/s640/IMG_4150.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiANO4hDahrC3QnrD8kSErUJl_nnZFI8ArStI7tEUwuXmRMTXMjMSMkJlvakHCPHaO67dCGW417f1uUTyMBU4Ye0IC8jAXfaa_KEDlWoUuPtGMojpDd0sPLQ5nAWQLBbnusCG2uNDWbMtI/s16000/IMG_4150.JPG" /></a></div>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-26724126275967715062020-10-02T02:00:00.063-04:002021-08-10T08:50:07.278-04:00Carter Super Wheel Go Kart Restoration<span face=""arial" , "helvetica" , sans-serif"><b>Carter Go-kart Project</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUw7i43RECi74RGVCI-wl_ipmRaKcE8mM6jKnyV380oQxziIv5yn0sd97FTSHeLPxl0FChC47UfUF5IX1ga0vKPaGPD-682X4iSeWRH0F475KI6Q222WDB2R7urTC0-dIqN1NEUTkRMmo/s640/IMG_4778.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUw7i43RECi74RGVCI-wl_ipmRaKcE8mM6jKnyV380oQxziIv5yn0sd97FTSHeLPxl0FChC47UfUF5IX1ga0vKPaGPD-682X4iSeWRH0F475KI6Q222WDB2R7urTC0-dIqN1NEUTkRMmo/s16000/IMG_4778.jpg" /></a><br />
I stumbled upon three go-karts that had been sitting outside for far too long. The price was right, but the project was big. This is the restoration of a Carter Super Wheel.<br />
<a name='more'></a><p>I started with the Carter as it was the only live axle of the bunch. It needed a new engine, clutch, tires, and a seat
at a minimum. <br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQ_rTEShyqZRYkgwD_IBKGRRlz9Fj6ucyNvTN1bfq0Ch2OfM3DoHMK-ZX1wLpffUQR81A0Fh4HgFaTs5_P6FlExlFlYQI4dF9f1kBaTJ0BodlMJOgRpBr68jwJXl4zx9yeu2q4LNZsORA/s1600/IMG_1607.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQ_rTEShyqZRYkgwD_IBKGRRlz9Fj6ucyNvTN1bfq0Ch2OfM3DoHMK-ZX1wLpffUQR81A0Fh4HgFaTs5_P6FlExlFlYQI4dF9f1kBaTJ0BodlMJOgRpBr68jwJXl4zx9yeu2q4LNZsORA/w640-h480/IMG_1607.JPG" width="640" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I restored the red Carter on the left.<br /></td></tr></tbody></table><p>
<b>Purchasing:</b><br />Kart Frame - free (depending on your area $60-10 for a non-running kart)</p><p>Engine/Clutch<a href="https://www.harborfreight.com/65-hp-212cc-ohv-horizontal-shaft-gas-engine-epa-60363.html">:<br />Engine 6.5hp 212cc</a> - $100 (HF has since increased the price and discontinued coupons)<br />
<a href="https://www.amazon.com/FDJ-Bore-40-41-Chain/dp/B01D4L6OSI/ref=sr_1_4?keywords=Go+Kart+Centrifugal+Clutch+10+Teeth&qid=1556838814&s=gateway&sr=8-4">10 tooth Sprocket Clutch (Amazon)</a> - $23<br />Alternative - <a href="https://www.gopowersports.com/10t-3-4-bore-max-torque-centrigugal-clutch-41/">Max-Torque Clutch</a> - $34<br /> Alternative - <a href="https://www.ebay.com/itm/Go-Kart-Minibike-Fun-Kart-Centrifugal-Clutch-3-4-10-Tooth-40-41-Free-Shipping-/400949247098?vxp=mtr&hash=item5d5a6ffc7a">Clutch - Go Kart Minibike Centrifugal Clutch</a> - $18<br />
5/16" x 3/4" 24 tpi bolt for output shaft - $0.18<br />
5/16" fender washer - $0.18<br />
5/16" lock washer - $0.18 <br />
<a href="https://www.amazon.com/Drive-Chain-Roller-Feet-Motorcycle/dp/B074MKKWTD/ref=sr_1_4?keywords=%2340+roller+chain&qid=1551794799&s=automotive&sr=1-4">#40 roller chain 10'</a> - $10 (chain # depends on the sprocket)<br />
#40 master links - $3 (I went ahead and got a chain breaker that I used to put the chain back together without a master link)</p><p>Engine Mounting bolts: <br />(4) 5/16 - 18tpi x 1 1/2 - $1.68<br />(4) nylon nuts 5/16 - 18 tpi - $0.16<br />(4) 5/16-18 washers - $0.21<br />
<br />
Seat:<br />
(2) <a href="https://www.lowes.com/pd/Hillman-5-16-in-x-1-1-2-in-Zinc-Plated-Coarse-Thread-Hex-Bolt-4-Count/3024617" target="_blank">5/16"-18 1.5" long bol</a>t - $1.68<br />
(2) <a href="https://www.lowes.com/pd/Hillman-5-16-in-x-18-Galvanized-Steel-Hex-Nut/3037543" target="_blank">5/16"-18 nut </a>- $0.21<br />
(4) <a href="https://www.lowes.com/pd/Hillman-5-16-in-x-Zinc-plated-Standard-SAE-Flat-Washer/3058559" target="_blank">5/16" washers </a>- $0.14<br />
<a href="https://www.amazon.com/FoamTouch-Upholstery-Cushion-Standard-Replacement/dp/B00TSVJDUK/ref=sr_1_7?dchild=1&keywords=3%22+upholstery+foam&qid=1586351208&sr=8-7">3" Upholstery foam </a> - $40 (I had leftover from another project) <br /><a href="https://www.amazon.com/gp/product/B01MRX23PK/ref=ppx_yo_dt_b_search_asin_image" target="_blank">Gray vinyl</a> - $12<br />T-nuts and staples<br /></p><p>Tires/Wheels:<br />
<a href="https://www.walmart.com/ip/HI-RUN-Stud-Super-Tire-4-10-3-50-5-2PR/39087988?athcpid=39087988&athpgid=athenaItemPage&athcgid=null&athznid=PWBAB&athieid=v0&athstid=CS020&athguid=0e9e2c8e-881-16977ae0614606&athena=true">Tires</a> - $7 ea. (4) - 4.1/3.5-5<br />
<a href="https://www.walmart.com/ip/Hi-Run-Tube-4-10-3-50-5-TR87/39087099">Intertube</a> - $6.50 (4)<br />
<a href="https://www.bmikarts.com/5-Split-Rim-2-1316-Bolt-Pattern_p_1572.html">Steel wheels</a> - $12 (x4) [don't get wheels from Harbor Freight]<br />
<a href="https://www.bmikarts.com/Wheel-Hub-with-4-38-Bolts-on-a-3-12-Circle-Includes-58-Bearing_p_7382.html">Wheel Hub</a> - $15 (x2)<br />
<a href="https://www.bmikarts.com/High-Speed-Wheel-Bearing-with-Snap-Ring-58-x-1-38_p_1608.html">Flanged Bearing</a> - $2 (x4)<br /></p><p>Paint:<br />(1) Rustoleum silver spray paint - $6<br />(1) Rustoleum Primer - $6<br />(2) Rustoleum blue spray paint - $6<br /></p><p><b>Total Cost: $365.08</b><br />
</p><div>
<b>References:</b><br />
<a href="https://www.reddit.com/r/gokarts/comments/ai0z31/do_not_buy_the_go_power_sports_34_inch_clutch/">clutch engages when motor starts </a><br />
<a href="http://www.diygokarts.com/vb/forumdisplay.php?f=6&order=desc&page=3">DIY Go Carts forum </a><br />
<a href="http://www.hfqpdb.com/">HF coupons</a> - don't pay more than $100 for engine<br />
<a href="http://www.hfqpdb.com/coupons/84_ITEM_6.5_HP__212_CC__OHV_HORIZONTAL_SHAFT_GAS_ENGINES_1551474652.7676.png">Engine coupon $100 </a><br />
<a href="https://www.bmikarts.com/">BMI for parts</a><br />
<a href="https://www.gopowersports.com/">Go Power sports for parts</a><br />
<a href="https://www.ombwarehouse.com/">OMB warehouse for parts </a><br />
<a href="http://northerntool.com/">Northern Tool for parts</a><br />
<a href="https://gokartguru.com/images/Go_Kart_Drive_Line.htm">Kart Performance Estimator </a><br />
<br />
<b>Speed Calculator:</b><br />
<a href="http://www.diygokarts.com/speed-calculator.html">calculator </a><br />
3600 max rpm (governed 212 cc predator) / 7.2 (gear reduction for 10t and 72t)= 500<br />
<br />
500x20 (tire diameter) x3.14 (pi for circumference)= 31400<br />
<br />
31,400/12 (inches to feet)= 2600<br />
2600/5280 (feet to miles)= 0.5<br />
.5x60 (minutes to hours)= 30 miles/hour.<br /></div><p>
<span face=""arial" , "helvetica" , sans-serif"><b>Introduction</b></span><br />
The first step was assessing the kart and figuring out what I
needed. I ended up stumbling on another <a href="https://withwardworks.blogspot.com/2019/11/streaker-go-kart-project.html" target="_blank">project kart</a> that I started
before this one that needed considerably less work. It was complete
and even had an engine (that ended up not running).</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg87rOtgeiLbyBO6bREDS9RSl9DFSGKOjSMTQy4qkltDpQsWC-wxhldYoueSrAsR5YTxYpkHK5S5dELxsipMjwxX_8rgvqVjvTvJJZIeHfTdRD2IMv2Of3crq2KB3fSaGfNB6fXTG3fHVs/s1600/57421416034__8E86D8B5-0811-4DDA-A522-55E169CE7A28.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg87rOtgeiLbyBO6bREDS9RSl9DFSGKOjSMTQy4qkltDpQsWC-wxhldYoueSrAsR5YTxYpkHK5S5dELxsipMjwxX_8rgvqVjvTvJJZIeHfTdRD2IMv2Of3crq2KB3fSaGfNB6fXTG3fHVs/s320/57421416034__8E86D8B5-0811-4DDA-A522-55E169CE7A28.JPG" width="240" /></a></div><p>This one was a red Carter Brothers Super Wheel live axle with band brakes. The wheels are 4.1x3.5-5. It's 5'-2" long with a 46" wheel base.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Frame</b></span><br />
I stripped the frame down, removing the engine, wheels, and miscellaneous
parts, cleaning the frame with a degreaser, then sanding it down. I
used sand paper, a grinder, a wire brush, and a pneumatic die grinder.<br />
<br />
The die grinder sanded it down quickly, and first I went over any
heavy rust with a grinder. I used a wire brush and 80 grit pads for
crevices and corners. Portions that weren't rusted I used 220 grit sand
paper and scotch brite pads.<br />
<br />
Welding occurred at this point. The Carter was missing 3.75" out of
the frame just in front of the rear axle. Who knows why. It looks like
after that piece was cut out it was still used, cracking two other frame
connections.<br />
I smoothed the cuts with a grinder and welded in a filler piece, 1"
tube. I was very careful to match the filler piece with the cut out,
leaving no gaps. First I ground down the cuts on the cart to where they
were straight. Then I made measurements, finding the widest spot, then cut
the filler pipe. After that it was a lot of grinding and checking to
make sure the filler pipe was a snug fit with no gaps.<br />
Any rough spots in the welds were ground down.<br />
<br />
The steering shaft was rusted solid on the Carter.
Penetrating fluid over a couple of days didn't loosen the shaft. I resorted to a very large pipe on the steering fork for leverage. It
did bend the steering fork a bit, but I used a large crescent wrench to
straight it out. At first the shaft would just move a couple inches, then a
little more as I worked it back and forth until I got the full range of motion.<br />
<br />The Carter had an adjustable seat with places for bolts on each side. It
only had 1 bolt that was heavily rusted so I replaced it with two new ones. <br />
<br />
I degreased all the parts of the frame again, primed, and then painted
everything. I left the live axle in place and taped it off. I painted the bottom, waited two days, painted the top,
waited two more days and reassembled. I painted the frame,
spindles, and tie rods blue. The brake and accelerator linkages
metallic silver, and the steering wheel silver. One can of primer covered the cart, with two cans for the color.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbBbJYnHAxG8XFxA8wF9MzzvCtr3q3kPdku5UGyPpiB4tkQwqnnotmPW06C0w6em1pkX8x6q-X2O24R7eB0zTyEP5jHPEjL0oIYLCKY7nMaJOle0sAZaIf6SYA_kEIt-geQOFtHKn4Tr8/s640/IMG_2949+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbBbJYnHAxG8XFxA8wF9MzzvCtr3q3kPdku5UGyPpiB4tkQwqnnotmPW06C0w6em1pkX8x6q-X2O24R7eB0zTyEP5jHPEjL0oIYLCKY7nMaJOle0sAZaIf6SYA_kEIt-geQOFtHKn4Tr8/s320/IMG_2949+copy.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCoKQx9r71cNmXbDOGhSh0u-5jMY7VdZyEDNGn38mwxQ9tD_E3PVVnrMaT8YvI3UnBv-etPA23fKRScohG0GD29eRTuElCMuUpXprJzAufgfcBUud5k1qNh5eFyO9yU1BguKhm5ixF5GE/s640/IMG_2950+copy.jpg" style="margin-left: 1em; 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text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-1vVWtQeBqN3cRCLwfGIFijvGGHlaQwsxOhiKn3xkCxwnG1nYzctx5bJd9_DAbX8PPBB0nLlxqGSaPlZu8GtxtX9e1d1WBNczkOhI2Lp9-8CPzzmrLkALPkFh30vD256iiiNGKJAf5Ak/s640/IMG_2988+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-1vVWtQeBqN3cRCLwfGIFijvGGHlaQwsxOhiKn3xkCxwnG1nYzctx5bJd9_DAbX8PPBB0nLlxqGSaPlZu8GtxtX9e1d1WBNczkOhI2Lp9-8CPzzmrLkALPkFh30vD256iiiNGKJAf5Ak/s320/IMG_2988+copy.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8uSreSCnJno5oVu7Sa5tTYGRiND2tCrBne3WweA8mQxD_6LIzkw4DQxicCbwJkGzmx4patVBW_sU1IHPZcvWPvRg5ErBAfPEoLOTQ12o8pPS5pCkDduNEfrBcfEjiwR8U05oCbKUzTyo/s640/IMG_E2976+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8uSreSCnJno5oVu7Sa5tTYGRiND2tCrBne3WweA8mQxD_6LIzkw4DQxicCbwJkGzmx4patVBW_sU1IHPZcvWPvRg5ErBAfPEoLOTQ12o8pPS5pCkDduNEfrBcfEjiwR8U05oCbKUzTyo/s320/IMG_E2976+copy.jpg" width="320" /></a></div><p><span face=""arial" , "helvetica" , sans-serif"><b>Engine</b></span><br />
The motor was a Briggs & Stratton flat head. The engine and
clutch were no good. The new engine came from Harbor
Freight. It's a lower cost knock off of the Honda GX200 engine. You can't beat
the 212 cc Predator engine. It has a compression Ratio of 8.5:1, takes
fuel type: 87+ Octane. The engine oil capacity: 0.5 Quarts which is 16 ounces. Fuel capacity is .9 Gallons.<br />
</p><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7IADh0vhRmKb33hn6L5G1rOxBijH1OJ02jDNLb3VGNUXYc0CU2kYRCO4pgTSwuQkxIQZaLfjjN2GsMmcH83luzI3aJilC5nvEcTtCVXq5QcBooT_B9C1CwULpXPHVMskvh8uJW0R3BqE/s1600/IMG_1636.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7IADh0vhRmKb33hn6L5G1rOxBijH1OJ02jDNLb3VGNUXYc0CU2kYRCO4pgTSwuQkxIQZaLfjjN2GsMmcH83luzI3aJilC5nvEcTtCVXq5QcBooT_B9C1CwULpXPHVMskvh8uJW0R3BqE/s320/IMG_1636.JPG" width="320" /></a></div>
<br />
It's a 3/4" output shaft with a 3/16" keyway, which matches the clutch
that came with the project. The Predator does come with key stock. <br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRPcu_WN3jdLm7hrBejo-hS9WkeqtuddyVWn0SHhPb85P8fseqeH8FdcSJo26T2zeMueF6wQjzNMW9RNmeEWNuXkZK3JXPWB9IDxemaNSNXz4hCrLkDrbkVDxG3q0Vh-mr90FaQQsG6Es/s1600/IMG_1640.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRPcu_WN3jdLm7hrBejo-hS9WkeqtuddyVWn0SHhPb85P8fseqeH8FdcSJo26T2zeMueF6wQjzNMW9RNmeEWNuXkZK3JXPWB9IDxemaNSNXz4hCrLkDrbkVDxG3q0Vh-mr90FaQQsG6Es/s320/IMG_1640.JPG" width="320" /></a></div>
I read a lot of posts like <a href="http://www.diygokarts.com/vb/showthread.php?t=18571">this one </a>and <a href="http://www.diygokarts.com/vb/showpost.php?p=239043&postcount=7">this one</a>
that the factory spring is insufficient with a kart throttle cable. I
loosened the tension nut on the throttle and while it would move freely,
it wouldn't return. I loosened it even more and it easily returned with
the stock spring. It comes out of the box with the nut tightened down.
Keep loosening it until
the throttle returns automatically. <br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgACit3vjS5sU2KJeEckUo9RzoIAxB2B-LMMpGQTdOmd5RzNBQ9dS4OvJjsIRLULcBmn5ETdiL2Vc3kfSec6UTTVaMRvC5iR_Eb2ukZ8MUpvj16khVeO75uOBsYxBCWg-RLdvKw-ywAdw4/s1600/IMG_1642.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgACit3vjS5sU2KJeEckUo9RzoIAxB2B-LMMpGQTdOmd5RzNBQ9dS4OvJjsIRLULcBmn5ETdiL2Vc3kfSec6UTTVaMRvC5iR_Eb2ukZ8MUpvj16khVeO75uOBsYxBCWg-RLdvKw-ywAdw4/s320/IMG_1642.JPG" width="240" /></a></div>
The Predator engine has a low oil sensor, but in a kart, just taking a
corner can trip the sensor and shut down the engine. The oil sensor can
be simply unplugged. It's a yellow wire coming out of the relay box that
has a connection to a yellow wire going into the crank case. The wire
from the relay can be
connected inline to ground with a momentary push button or toggle switch
to use
as a kill switch.<br />
<br />
There is a cable clamp for the throttle cable and a cable anchor for the cable.<p>
<b>Engine Break-In:</b><br />
After mounting the engine, fill the oil
and check the level. The Predator takes 16 ounces. Give the pull start a
slow pull to make sure everything turns
over okay. Check your engine max throttle screw because the factory
sets it pretty low. I left mine all the way in to start. Fill the
tank with gas.<br />
<br />
To
start the engine, just turn the red knob to ON, turn on the gas valve with the
black lever, turn the grey lever to choke and pull the rope. While some
recommend a 3 hour break in, I rode the kart for about two hours and changed
the oil. It's recommended to NOT run the engine wide open until after break in.<br />
I leave the choke on for just about 30 seconds, then shut it all the way off.<br />
<br />
For future reference, <a href="https://www.youtube.com/watch?v=kMw91fiIXNc">cleaning the Predator carb</a>. <br />
<br />
<span style="font-family: inherit;"><span face=""arial" , "helvetica" , sans-serif"><b>Throttle & Brake Cables</b></span></span><br />
The Carter throttle cable was in fine shape, or so it looked. I didn't
try it until the kart was assembled, and the cable would not slide
through the sheath. I put WD-40 in each end of the sheath and let it sit
overnight. The next day I took the cable out and greased it. After that
it worked fine.<br />
If you need to replace the throttle cable, bicycle cable is cheaper.<br />
If your kart uses cable for the brakes, use go kart brake cable. It lasts longer and is safer. Many carts use steel bar anyway.<br />
<br />
When tensioning the throttle cable, the gas pedal should hit exactly at
full throttle, match them up or adjust them until it matches.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Clutch</b></span><br />
I'm using a 10 tooth clutch sprocket. The 5/16" bolt and washers threads into the end of the output shaft of the engine to
keep the clutch on the shaft. The length depends on where the sprocket
seats. You want at least a half inch threaded into the output shaft with the clutch teeth and sprocket teeth lining up.<br />
<br />
Many clutches have a set screw. This should screw into the keyway. You don't want to mar the shaft.<br />
<br />
The keyway is the slot. The locking part is the key. A piece of 1/4" x
1/4" keystock is what's usually used. It's just square steel rod that is
cut to desired length.<br />
<br />
The Predator comes with a keystock, and the clutch I bought has a built in keystock. <br />
<a href="https://www.bmikarts.com/Go-Kart-Axle-Key-Stock">Keystock</a><br />
<a href="https://www.homedepot.com/s/KEYSTOCK?NCNI-5">home depot keystock </a><br />
<br />
Oil the clutch bushing often. You can run a spacer or<a href="https://www.bmikarts.com/Steel-Split-Locking-Collar-34-1-or-1-14_p_1101.html"> lock collar</a> to keep the clutch from shifting towards the engine. I haven't done this, and also haven't had a problem.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Sprockets & Chain</b></span><br />
The Carter uses a #41 chain with a 54 tooth sprocket. <br />
<a href="http://www.gizmology.net/sprockets.htm">chain size information</a><br />
<br />
Allow between 1/4 inch and 3/8 inch flex for proper adjustment, if you
have more than 1/2" flex it needs to be adjusted as the chain will come off. Loosen the engine
mount bolts and slide the engine, or add washers to the bolts to lift
the engine.<br />
<br />
I bought chain from Tractor Supply, #40. #40 chain will work in the place of #41, but #41 won't work in place of #40.<br />
<br />
#41 has a .5" pitch & 6.35 mm width between plates<br />
#40 has a .5" pitch & 7.9375 mm with between plates<br />
<br />
I used this <a href="https://cutpriceracing.com.au/store/Page17/">chain guide</a>
to make sure the two could interchange. I used a chain breaker to press
out studs and then press them in. If you don't have a chain breaker you
can use a punch and nut and master link. The master link opening
should point towards the back of the kart. <br />
<br />
<b>Gearing:</b><br />
For gearing 6:1 is the commonly recommended ratio for tires up to a 15" tire on a fun kart.<br />
<br />
Once you get taller tires, its more difficult to get the kart moving
with that gearing. Gearing is the drive axle sprocket teeth divided by
the clutch sprocket teeth. The Carter has 54 teeth and 10 teeth. This is
a 5.4:1 ratio. The lower the ratio the less acceleration, but more top
end.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Brakes</b></span><br />
The Carter brake rod had been installed wrong, which wore a notch into
the rod and prematurely wore down the top of the band brake. The rod ran
under the bracket when it should have run above. I had to have the
notch welded to fill it in, then ground it down. <br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Wheels & Tires</b></span><br />
The Carter had one wheel rusted through. The kart has a 3" bolt
pattern, and that's not a common pattern you can buy for a wheel.<br />
I bought steel split wheels with a 2-13/16" bolt pattern. While that
won't quite fit my rear hubs, filing the wheel hole just 1/8" will fix
that.<br />
<br />
I needed to buy at least one hub, and went ahead and bought two just so
the front hubs would match on the Carter. This would also match the
wheel bolt pattern.<br />
<br />
I considered buying all new hubs for the Carter as I preferred
galvanized wheels just for aesthetics, but that would increase my price
quite a bit and the site I was browsing didn't have 3/4" live axle hubs
so I scrapped that idea.<br />
<br />
With 5" diameter wheels, the max height is 12". 6" wheels are more common, so the tires are cheaper. <br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Steering Wheel</b></span><br />
The steering wheel on the Carter was metal and rusted pretty good in one
spot. I used expanding foam to fill the inside and then applied body
filler. Hopefully the foam is stiff enough. Even with no backing body
filler will take a while to start bubbling, with the foam backing I hope
it will suffice.</p><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-oBxJkfX_ow-jABL7rgXz25nXCRXmYWEDl_OTTP0Vh0q3T5Ut1ioRpAVclfgHudvYntr9JNkj-7z_1YWj0ibKbqPBJxZ2dmMLqIEDYy4YYl39GMtxKWNn9gx3blZgh3D86maqTzDOUzU/s640/IMG_2975+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-oBxJkfX_ow-jABL7rgXz25nXCRXmYWEDl_OTTP0Vh0q3T5Ut1ioRpAVclfgHudvYntr9JNkj-7z_1YWj0ibKbqPBJxZ2dmMLqIEDYy4YYl39GMtxKWNn9gx3blZgh3D86maqTzDOUzU/s320/IMG_2975+copy.jpg" width="320" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTMnlPqhb09g1GgOCf1xtKtdEZrs1noaaBt6vxPxj94eTSZwypZAun_llzvyBYgTtFB-vM3BWyz_k5Owq17QJUUYhjj5h9lk86KSleIZ2UC7H5gkaeZ3skyO4JNXD5i0tv2aASxw2u-TU/s640/IMG_2981+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTMnlPqhb09g1GgOCf1xtKtdEZrs1noaaBt6vxPxj94eTSZwypZAun_llzvyBYgTtFB-vM3BWyz_k5Owq17QJUUYhjj5h9lk86KSleIZ2UC7H5gkaeZ3skyO4JNXD5i0tv2aASxw2u-TU/s320/IMG_2981+copy.jpg" width="320" /></a><br />
<span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsZm-9Dog9vdwRMYTEMd8raeC2oUuRjy2Q3qbPrS_9eVrirFJsLGaxgnstVduqNSWz46NJifJxBg5wm0oBG_93hOHvVGbc-pVxK5JxiRZyrKjQWhpK-yiElRCxbwPLu4ouufQCu73dEyU/s640/IMG_2982+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsZm-9Dog9vdwRMYTEMd8raeC2oUuRjy2Q3qbPrS_9eVrirFJsLGaxgnstVduqNSWz46NJifJxBg5wm0oBG_93hOHvVGbc-pVxK5JxiRZyrKjQWhpK-yiElRCxbwPLu4ouufQCu73dEyU/s320/IMG_2982+copy.jpg" width="320" /></a> <br /></b></span></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Kill Switch</b></span><br />
The kill switch on the kart still worked. Here are <a href="http://www.diygokarts.com/vb/showthread.php?t=10983">two</a> e<a href="http://www.diygokarts.com/vb/showthread.php?t=35160">xamples</a>.
I ran a wire from the low oil sensor wire, which i unplugged and capped
on the engine side. On the relay side, I connected by 14 gauge wire
from the kill switch, using the same cover. My switch is self grounding,
but if your toggle switch has two blades, you would connect the wire
from the relay to one, and then run a wire from the other blade to a
screw in the kart for a ground.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Seat</b></span><br />
The seat is 3/4" plywood and 3" upholstery foam. I cut the plywood to
fit the seat and used the existing holes, marking where to install
t-nuts. I cut the foam to fit the plywood, then glued the foam to the
plywood. It's best to cut the foam 1" wider than the wood all the way
around.<br />
While you can find cheaper foam, upholstery foam is firmer which means
it won't feel like you're sinking all the way through it when you sit on
it.<br />
<br />
I stapled one side of the vinyl to the plywood, stretched it across and
stapled the other side. I folded the vinyl at the ends. There isn't a
great way to work out the wrinkles. For the curved back portion, i
stapled in two pleats on each side to make it look uniform.<br />
<br />
It's fine to staple a bit and then have to pull up a few staples and redo it. </p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8MX0L14Kn4Rw0-N5QI8NZchiHvsjIYXkzACw9AK5E-KukDuCh4aBVWlzJa40GobPxSGgJQFjz3ceyS6neonqtCWNCpR_aVghD7M7rzc8Yxb7ILTAvjgu1zL0plhICm57DMXI84zgjs_I/s640/IMG_2943+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8MX0L14Kn4Rw0-N5QI8NZchiHvsjIYXkzACw9AK5E-KukDuCh4aBVWlzJa40GobPxSGgJQFjz3ceyS6neonqtCWNCpR_aVghD7M7rzc8Yxb7ILTAvjgu1zL0plhICm57DMXI84zgjs_I/s320/IMG_2943+copy.jpg" width="320" /></a><br />
</p>
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpYAUslgQNqIO0RKIrF-2aZ77ye7R1dIltwmoX0vmzVf2BK1KP2EVuRmmRaTh9CuRcYQ9FWkKz5Bonn6lvWB92-HM_3fkS88rEHoDxR5acMOdTLEgAo-cujNpCz1M-Z1MTlTQJw0UuA_E/s640/IMG_2946+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpYAUslgQNqIO0RKIrF-2aZ77ye7R1dIltwmoX0vmzVf2BK1KP2EVuRmmRaTh9CuRcYQ9FWkKz5Bonn6lvWB92-HM_3fkS88rEHoDxR5acMOdTLEgAo-cujNpCz1M-Z1MTlTQJw0UuA_E/s320/IMG_2946+copy.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy_aZlcxlFhpTyYDC9Xt6d27hyphenhyphen9vFzMKI5SZEB2gpikE02cxfcWGs2d7gIVVYyaryY9Dr52z6TCnb-W74WoDCud-I7PHWCS4LgfCHz1LFmH8OvegKz-uuG21dsVOPDr5OLVlxxvz2Q8NQ/s640/IMG_2947+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhy_aZlcxlFhpTyYDC9Xt6d27hyphenhyphen9vFzMKI5SZEB2gpikE02cxfcWGs2d7gIVVYyaryY9Dr52z6TCnb-W74WoDCud-I7PHWCS4LgfCHz1LFmH8OvegKz-uuG21dsVOPDr5OLVlxxvz2Q8NQ/s320/IMG_2947+copy.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLtFcw_BqNoCMrFm_qOyb5Q1h12gClgL3YXRYfbA264qzNoiH9UHn6d_JdouIs1OMQZKJIKficXb39sG9Rm2E6Xt3uxZHjg3Gmi3tpyV83p3pbh2tFUwDQj6r-gPez2bagacDKrU1tto4/s640/IMG_2948+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLtFcw_BqNoCMrFm_qOyb5Q1h12gClgL3YXRYfbA264qzNoiH9UHn6d_JdouIs1OMQZKJIKficXb39sG9Rm2E6Xt3uxZHjg3Gmi3tpyV83p3pbh2tFUwDQj6r-gPez2bagacDKrU1tto4/s320/IMG_2948+copy.jpg" width="320" /></a></div><p><span face=""arial" , "helvetica" , sans-serif"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHonAFiMeI98HqaW8GVL3dj03majjiB5hQki5CM5Q_4nUmoTttGMdsutrgR3UpuAelDeTllBgem_i357Sjd1TYncoBW4gPllh9OdPAGsYH7mkYLphHAoI7njGJdITeMC9rS4wbPaeuHK4/s640/IMG_2977+copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHonAFiMeI98HqaW8GVL3dj03majjiB5hQki5CM5Q_4nUmoTttGMdsutrgR3UpuAelDeTllBgem_i357Sjd1TYncoBW4gPllh9OdPAGsYH7mkYLphHAoI7njGJdITeMC9rS4wbPaeuHK4/s320/IMG_2977+copy.jpg" width="320" /></a> <br /></b></span></p><p><span face=""arial" , "helvetica" , sans-serif"><b><span face=""arial" , "helvetica" , sans-serif"><b>Reassembly</b></span><br /></b>Putting everything together isn't difficult as there aren't that many parts. I greased the rear axle before putting the wheels on. Taping sockets/wrenches will help prevent scratching the paint during the process.<br /><b></b></span></p><p><span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span><br />
My only regret is not applying a bit of filler to the
floor pan to smooth it out a bit. From sitting in a field for so long it
has some minor pitting. Other than that I like the results and it's a lot of
fun to drive.I used to have a CB antenna that I threw away a
couple years ago. It would have been perfect to modify into a flag mount.</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq8GH7Np0xP_lHtj6mSA7LMxslYidCbPawYXJoOUR6u00rMpVnJbX_hGOxCc6vPzvDNe-varWF7JF_0fzQZDiXLUth6ioaLamitt6TXt9D6j6lay0dqD1XWDWOosK1KLWcarNB10ExKyA/s640/IMG_4776.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiq8GH7Np0xP_lHtj6mSA7LMxslYidCbPawYXJoOUR6u00rMpVnJbX_hGOxCc6vPzvDNe-varWF7JF_0fzQZDiXLUth6ioaLamitt6TXt9D6j6lay0dqD1XWDWOosK1KLWcarNB10ExKyA/s320/IMG_4776.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1aKMHd4-q7Yc_AJPnTbJU89Mex8PEaVq9ETpyecItbnM4bEzzQZcNHHjFvqZTTgdOD77oIW1Cvt5YL7pCfMeGT7HIaxA-hPbRCvhRcq4xUJFzbWO72FqcpMQh4yV_MOVmGQ9WDRwDBkw/s640/IMG_4779.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj1aKMHd4-q7Yc_AJPnTbJU89Mex8PEaVq9ETpyecItbnM4bEzzQZcNHHjFvqZTTgdOD77oIW1Cvt5YL7pCfMeGT7HIaxA-hPbRCvhRcq4xUJFzbWO72FqcpMQh4yV_MOVmGQ9WDRwDBkw/s320/IMG_4779.jpg" width="320" /></a></div><p></p><p>I still have a Kenbar Streaker and a unidentified scrub brakes kart. I'm thinking the single axle Streaker is a great candidate for a dual engine setup. Unfortunately Harbor Freight has raised the prices on engines and stopped coupons, which will significantly increase the cost of future projects.<br /></p>WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com2tag:blogger.com,1999:blog-5852505765428063006.post-65009670612705222382020-10-01T02:00:00.187-04:002020-12-27T20:50:55.797-05:00Build a Work Bench<span face=""arial", "helvetica", sans-serif"><b>Work Bench</b></span><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5_QokaEuz_wU3p6XWkcs3fTeAM79cgofkJG46VSnBGX7E1pjMzeWBv_L2_ir7lPSezr75aZimhXtCnbzAHd5l_YsTfYdvy8KyBRaQI-qgm9k54RV3scC-jGtt1hY1XAwgUwc1U6P4DGw/s640/IMG_4160.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5_QokaEuz_wU3p6XWkcs3fTeAM79cgofkJG46VSnBGX7E1pjMzeWBv_L2_ir7lPSezr75aZimhXtCnbzAHd5l_YsTfYdvy8KyBRaQI-qgm9k54RV3scC-jGtt1hY1XAwgUwc1U6P4DGw/s16000/IMG_4160.jpg" /></a><br />
I've never had a real work bench. It was time to make the centerpiece of my shop.<br />
<a name='more'></a><p>
A couple of years ago, I decided to rearrange my shop. Instead of putting things where they fit, I started a plan from scratch, arranging the shop to fit work flow. I <a href="https://withwardworks.blogspot.com/2019/04/shop-electrical-outlet-upgrade.html" target="_blank">upgraded electrical</a>, the <a href="https://withwardworks.blogspot.com/2018/01/shop-lighting-upgrade.html" target="_blank">lights</a>, painted the walls, and added a ceiling. The one thing missing after redoing the shop was a workbench. It was the centerpiece of my shop in the plans, it just didn't exist yet.<br /> <br />The top is 2x4s with a 2x4 frame and 4x4 posts. There are drawers along each side and a plywood bottom shelf. I used a hitch receiver for a removable vise. I also have plans to create a system for retractable bench dogs. The top is 6'-3"x4'-0" and it's 42" tall.<br /></p><p><b>Buy List (Base Bench)</b><br /></p><ul style="text-align: left;"><li>(38) 2x4</li><li>(2) 4x4</li><li>(2) 4'x8'</li></ul><b>Drawers </b><br /><div><ul style="text-align: left;"><li>1.5" Aluminum angle for drawer pulls </li><li>(3) 26" Drawer slides</li><li>(2) 16" Drawer slides<br /></li></ul><p><b>Removable Vise<br /></b></p><ul style="text-align: left;"><li><a href="https://www.harborfreight.com/3500-lb-capacity-step-bumper-receiver-67159.html">Removable Vise</a></li><li><a href="https://www.harborfreight.com/hitch-mount-vise-plate-66260.html">Vise Mount Plate</a></li><li>(6) 3/8"x6" Carriage bolts / (6) Nuts / (12) Washers</li><li>$38</li></ul><b>Paint/Finish</b><ul style="text-align: left;"><li>(1) quart polyurethane</li><li>(1) quart paint</li><li>$20 </li></ul>Total Cost: $263 for the base work bench $365 with drawers, vise mount<br /><p><b>Cut List</b><br /></p><ul style="text-align: left;"><li>(38) 6'-3" 2x4 top</li><li>(2) 5'-8" supports (mortise ends)</li><li>(4) 3'-5" supports (mortise ends)</li><li>(2) 3'-6.5" bottom shelf support (mortise ends)</li><li>(4) 3'2" 4x4 legs (mortise top)</li><li>(1) 3'-7.5"x5'11" plywood bottom shelf</li><li>(2) 3'-2"x5.75" plywood (sides)</li><li>(4) 9.25" 2x4 drawer support (mortise end)</li><li>(2) 3'5.25" 2x4 drawer support (mortise ends)</li></ul><p>Drawers</p><ul><li>(5) 1'9"x5" drawer face</li><li>(10) 1'-6"x5" drawer sides</li><li>(5) 1'-6.5" drawer back</li><li>(5) 1'5.25"x1'6.5" drawer bottom <br /></li></ul><div><div>
</div>
<p>
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcZddYotIA57p_lnHPrB8pjTIsoYKaihsP2_aCEX5eQmxW4wahr3pyG3FqbmZmH4Zji1kWlmCsmgNnPUnIvwpv5BXLr8J1qhS5Fzfts6A4ClUfQAJwcrhtyLxU4GrTkiFsYZJiraR7TuE/s640/IMG_3085+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcZddYotIA57p_lnHPrB8pjTIsoYKaihsP2_aCEX5eQmxW4wahr3pyG3FqbmZmH4Zji1kWlmCsmgNnPUnIvwpv5BXLr8J1qhS5Fzfts6A4ClUfQAJwcrhtyLxU4GrTkiFsYZJiraR7TuE/s16000/IMG_3085+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">4x4 posts</td></tr></tbody></table><br /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUWWdeOEaO5Jhg8r9pAmKWTKaUlv_HfNuMDcbvUZNga6z0gueigpmJQqV3oA939FA76MfNjREd6JIjuMYocsVKdnRKKsT1-P_ZtL4p2TOn_bTWr3Do1rk6uWMl8p83wAMnu5vQiDsA2cY/s640/IMG_3084+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUWWdeOEaO5Jhg8r9pAmKWTKaUlv_HfNuMDcbvUZNga6z0gueigpmJQqV3oA939FA76MfNjREd6JIjuMYocsVKdnRKKsT1-P_ZtL4p2TOn_bTWr3Do1rk6uWMl8p83wAMnu5vQiDsA2cY/s16000/IMG_3084+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">2x4s</td></tr></tbody></table><p>I went through a lot of iterations for this bench. Mostly revising the top from plywood to 2x4s and debating on a sacrificial top. I started the project in Sketchup. A 3d model makes the construction much easier.<br />
I added a plate to mount a removable vise, bench dogs, and decided to add drawers. I have three drawers on one side and two on the other because of the vise.<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHUw9dqnEr838Dlyp7cHDFZdXgClvdHZ04WfA2zJNlN-h9cdxifvv435z_dOWelJ_Xo9mq4QahGDTZEJEHIuswmpchq5mrjlpZEgGqJFSNZ7IX0bSzBnV-KUrPF5HFriUYBqdPin6OJP0/s640/WorkBench02.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHUw9dqnEr838Dlyp7cHDFZdXgClvdHZ04WfA2zJNlN-h9cdxifvv435z_dOWelJ_Xo9mq4QahGDTZEJEHIuswmpchq5mrjlpZEgGqJFSNZ7IX0bSzBnV-KUrPF5HFriUYBqdPin6OJP0/s16000/WorkBench02.png" /></a><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV-cVHU-VcmdalM1AFWoPtaKpGUdvSZ1-5wYgcxMiKdG1W7YUdd0Dsjsk5lDcohFeZ8tSRZ9v_6SFdQG430DhNZ_gkeKfANzw_3EV3H01PzJPYocN2AgVVYxHfp_huXD5BF14DRa9RJsI/s640/WorkBench01.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="360" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiV-cVHU-VcmdalM1AFWoPtaKpGUdvSZ1-5wYgcxMiKdG1W7YUdd0Dsjsk5lDcohFeZ8tSRZ9v_6SFdQG430DhNZ_gkeKfANzw_3EV3H01PzJPYocN2AgVVYxHfp_huXD5BF14DRa9RJsI/s16000/WorkBench01.png" /></a><br />
The top of the table is at 42" tall. I made a cardboard mockup to make sure of the height before I started, but I knew 36" tall was too short. The table height is perfect when standing and the perfect height with a <a href="https://www.harborfreight.com/flame-design-bar-counter-swivel-stool-91200.html" target="_blank">standard bar/counter stool.</a></p><p>
<b>Structure</b><br />
The structure consists of 4x4 legs and 2x4 bracing. I decided to mortise and tenon the joints. I had never tried this type of joint before. I cut mortises first, then the tenon. The tenon should be no thinner than half the board thickness. The length of the tenon should be roughly four times the tenon thickness.<br /><br />
I
used a router to cut the tenons, .25" less all the way around with a
1.5" length.The router has a fair amount of tear out, doing it again I
would probably use a band saw.<br />
<br />
For the mortises, I cut
them out with 1" forstner bit, then a hammer and chisel for the corners.
I then test fit the tenons and trimmed as necessary for the fit. They
came out great considering it was my first time trying this joining
technique. It helped that they are blind/concealed.<br />
<br />
I then mortised braces into the 2x4 cross members. These are only 1" deep so the ends are concealed within the 2x4s.</p><p>In my build I did this later, but the top needs 2x4 cross braces. One at each end and two in the middle are sufficient. I added the bracing later as the 2x4 top was sagging. I shimmed each end to try to get the top back to level in my build. Building these braces in the beginning would have helped.<br />
<br />
The bottom shelf is plywood. I almost couldn't fit the shelf in place. I should have put it in place when assembling the table. Instead I added it when the structure was glued up and the top in place. I was close to needing to cut the plywood in half to fit. I got it to flex just enough to get it in.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8qIzmG6NrrY6ZmAP6QmAUGQw3jqfviySDe3-XdiK6sUM8Q9vGvinGNum6JLLsxp04cYkgVXYz5aHq8voHOzOHdrmutHQo-yjAaQ-06AIXaDyQgqCHPhyrz25CGSoeNnEuwHOEhzPO1cE/s640/IMG_3216+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8qIzmG6NrrY6ZmAP6QmAUGQw3jqfviySDe3-XdiK6sUM8Q9vGvinGNum6JLLsxp04cYkgVXYz5aHq8voHOzOHdrmutHQo-yjAaQ-06AIXaDyQgqCHPhyrz25CGSoeNnEuwHOEhzPO1cE/s320/IMG_3216+copy.png" width="320" /></a></p><p>I cut the 2x4s to length with a chop saw, cut the legs with a table saw,
two cuts front and back as the table saw doesn't cut deep enough for a 4x4.</p><p> </p><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiti4SUD41m4_8GJWHRsoUnM-NG1msbHq9FXoa7qSyyT4bU4nEUs1ZAmYUH5h8B8i6L7QXwRcL_E8rvNEYFmZf_ajSE4FXbnC5PNSbMLBdO3ZrTV1BstFnmLbXtjsb1vzNjnFXwkVcgV4w/s640/IMG_3093+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiti4SUD41m4_8GJWHRsoUnM-NG1msbHq9FXoa7qSyyT4bU4nEUs1ZAmYUH5h8B8i6L7QXwRcL_E8rvNEYFmZf_ajSE4FXbnC5PNSbMLBdO3ZrTV1BstFnmLbXtjsb1vzNjnFXwkVcgV4w/s16000/IMG_3093+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The future top.<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihETNf2i5L94-v0lDe2-FLzQrsuY8U5aUHVarCphQCd9fDPd6irENXkQ2A5osV2LBDuybsBb2nOBSx232sh-aZFHm0PqO85Rnk7MEgASjt841KN4FAUeqvZnEjWB_pANcFylFBU1kiM2g/s640/IMG_3098+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihETNf2i5L94-v0lDe2-FLzQrsuY8U5aUHVarCphQCd9fDPd6irENXkQ2A5osV2LBDuybsBb2nOBSx232sh-aZFHm0PqO85Rnk7MEgASjt841KN4FAUeqvZnEjWB_pANcFylFBU1kiM2g/s16000/IMG_3098+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Tenon</td></tr></tbody></table><p> </p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt9MY3gRM3qUlrIh0MwE5Eite6MwbhqL8EzLWCGT1cUY7IQmF6PY834sGjeBgVgMDYn7Qv0_i3drvQc2hYxzOZjG8Lvmws3lhEG4NM9m19bMRVuhy8eWwPG4dl4p95GW_tPRAlazoJpn8/s640/IMG_3099+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt9MY3gRM3qUlrIh0MwE5Eite6MwbhqL8EzLWCGT1cUY7IQmF6PY834sGjeBgVgMDYn7Qv0_i3drvQc2hYxzOZjG8Lvmws3lhEG4NM9m19bMRVuhy8eWwPG4dl4p95GW_tPRAlazoJpn8/s16000/IMG_3099+copy.png" /></a> <br /></p><p></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX_DYQ3O4rKHpaCAvfIsndsKsKHGKKFtAJdLolJwDAChHfhuq2nrZA0OipCAJqcUt1ypc36QbmeppOUU2dMOA_l-h3J8L-WwDy4sOZo9TxCj4OlvYiyT2I5U0GW45o8_3C7qIxEXJ41Zk/s640/IMG_3106+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX_DYQ3O4rKHpaCAvfIsndsKsKHGKKFtAJdLolJwDAChHfhuq2nrZA0OipCAJqcUt1ypc36QbmeppOUU2dMOA_l-h3J8L-WwDy4sOZo9TxCj4OlvYiyT2I5U0GW45o8_3C7qIxEXJ41Zk/s16000/IMG_3106+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Mortises were marked, accounting for the tenon.<br /></td></tr></tbody></table><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-7LU7mFC99YRoCjimf0UKmjvrox18VnX3FKwexPj0Pq3gf32dB-oL7EUkcwMJplNGbce4q-zt05zLdGK6nLPhW-_sDEJeoMwI2QNlsYP6wPHIsegblDFhwM1I6JrlqRfSlcGCtVZTIWY/s640/IMG_3107+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-7LU7mFC99YRoCjimf0UKmjvrox18VnX3FKwexPj0Pq3gf32dB-oL7EUkcwMJplNGbce4q-zt05zLdGK6nLPhW-_sDEJeoMwI2QNlsYP6wPHIsegblDFhwM1I6JrlqRfSlcGCtVZTIWY/s16000/IMG_3107+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Forstner bit to start the mortise.<br /></td></tr></tbody></table><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY8XIkad-akyPmJpp8T9VfNL32cq138Up9PyZRmoSLQrYj6xey5_uz-n7ovwwBGVPB2vqgQTrWsQLdK19AVU2iHoVYoXNqtDOJMoS0fpCbRJi5SxV46HlgAIcz-8WgBIyorzb51mDFPA4/s640/IMG_3105+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY8XIkad-akyPmJpp8T9VfNL32cq138Up9PyZRmoSLQrYj6xey5_uz-n7ovwwBGVPB2vqgQTrWsQLdK19AVU2iHoVYoXNqtDOJMoS0fpCbRJi5SxV46HlgAIcz-8WgBIyorzb51mDFPA4/s16000/IMG_3105+copy.png" /></a></p><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbvBsI2In7ZuqyeYxst6c6H_s3ezX7U2Cu-GFl2UFf1fkr5KNwxyk6z3n-TVqV5PW8cTroOMI8Vghss-KtWMYBEhmBr8fiMHLS0Sp6Wo2LE__TX7OV122TpWJbN8IaWP_VXWBr4FCn7dI/s640/IMG_3108+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbvBsI2In7ZuqyeYxst6c6H_s3ezX7U2Cu-GFl2UFf1fkr5KNwxyk6z3n-TVqV5PW8cTroOMI8Vghss-KtWMYBEhmBr8fiMHLS0Sp6Wo2LE__TX7OV122TpWJbN8IaWP_VXWBr4FCn7dI/s16000/IMG_3108+copy.png" /></a> <br /></p><p></p><p></p><p></p><p></p><p></p><p></p><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHueW6kBVL4f5g5LPoSUxjhQsKBeUotxHY2uGvpEoaBPvtHr6t90jxvReETqW9SQ0qgIkQJZ4Yn3Ku7odLxWIJtjI1CZkrUzRsQpFVJP3lQFkyw4WLNv4cR4QGIXE-zvKYIl_gISodVEU/s640/IMG_3109+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHueW6kBVL4f5g5LPoSUxjhQsKBeUotxHY2uGvpEoaBPvtHr6t90jxvReETqW9SQ0qgIkQJZ4Yn3Ku7odLxWIJtjI1CZkrUzRsQpFVJP3lQFkyw4WLNv4cR4QGIXE-zvKYIl_gISodVEU/s16000/IMG_3109+copy.png" /><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOdvKZjxDFWuzRtw5UinuJ-abTOniOA5kLWOs-m5oC4cC0sXhyphenhyphenWrdGUDHBSQikPSsmrWuFAu9vDNCWO17QU3xjPedXtVbHjQMgLx1YWrxZSb5ryMueCaU6-KImDzBCgqrNvT8f1BKbTIw/s640/IMG_3110+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOdvKZjxDFWuzRtw5UinuJ-abTOniOA5kLWOs-m5oC4cC0sXhyphenhyphenWrdGUDHBSQikPSsmrWuFAu9vDNCWO17QU3xjPedXtVbHjQMgLx1YWrxZSb5ryMueCaU6-KImDzBCgqrNvT8f1BKbTIw/s16000/IMG_3110+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Completed mortise</td></tr></tbody></table></a></p><p></p><p></p><p></p><p> </p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgebkCoV-0N4kqGBBe23g4sqbQNhdbGj_ih6ayy4yZgtGCBbVyjRt4j4XS-Bscq0_TFBRw4Zx-niV1sg21xWFEZtsJgzN5HZKi_OMFK_dmyOkJXJy332potgLhL4KfDliW7DeDzeT_PuPc/s640/IMG_3111+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgebkCoV-0N4kqGBBe23g4sqbQNhdbGj_ih6ayy4yZgtGCBbVyjRt4j4XS-Bscq0_TFBRw4Zx-niV1sg21xWFEZtsJgzN5HZKi_OMFK_dmyOkJXJy332potgLhL4KfDliW7DeDzeT_PuPc/s16000/IMG_3111+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Each post has (4) mortises.<br /></td></tr></tbody></table><p> </p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxMrMu3X6lz3_gF45Ax26Hiwtsm3NstqH0bsU21uRjMz0edyGUzmvKb-TyQ0X3fHRNnbPSDRPHP4e9p842hXoSvkW98L6jaUq0XCoQ4giyCKkwq-tCsdoMXv79cq_qYjv-d7YFin9k8OE/s640/IMG_3112+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxMrMu3X6lz3_gF45Ax26Hiwtsm3NstqH0bsU21uRjMz0edyGUzmvKb-TyQ0X3fHRNnbPSDRPHP4e9p842hXoSvkW98L6jaUq0XCoQ4giyCKkwq-tCsdoMXv79cq_qYjv-d7YFin9k8OE/s16000/IMG_3112+copy.png" /></a> <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3_QoIafRD87GkNAUKMkA5tb-VqsfB5B5_BiWdnXcTms54U7sJatph9knmpOS5czSOVYV3nMnbEKP3PG43lGyw_y0zyAg03KeIE8iGTT0EBxJJKsQQx8CAOIJh4ZH23fC2B13i9pOCU1Q/s640/IMG_3120+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3_QoIafRD87GkNAUKMkA5tb-VqsfB5B5_BiWdnXcTms54U7sJatph9knmpOS5czSOVYV3nMnbEKP3PG43lGyw_y0zyAg03KeIE8iGTT0EBxJJKsQQx8CAOIJh4ZH23fC2B13i9pOCU1Q/s16000/IMG_3120+copy.png" /></a> <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlBJnQ7gu0zzcddjFfDgeePyDr7ozEmZTdJU1FvHXGqKuy1b0ctPcOSjEuDsX0gtOUscl2PqamWRQDP5dIZDpNukbFwrgOL_q3PwQm_qcpuH_0HvuMbkDro0DXx7Z29iBFK-tjowzoGsA/s640/IMG_3122+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlBJnQ7gu0zzcddjFfDgeePyDr7ozEmZTdJU1FvHXGqKuy1b0ctPcOSjEuDsX0gtOUscl2PqamWRQDP5dIZDpNukbFwrgOL_q3PwQm_qcpuH_0HvuMbkDro0DXx7Z29iBFK-tjowzoGsA/s16000/IMG_3122+copy.png" /></a> <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC5t406AWBQA3yvK15bftHwjaK0LeK8lNnAxjtTLkyEQ3RfRFct-FJbeObjQO67DarLJTESM4l4hhlc8uRlZFwCiCfw3EJZkfwS9555B83G7tkv9wIInoidoo2VPmYnUWbM_FqdnfrFqU/s640/IMG_3124+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiC5t406AWBQA3yvK15bftHwjaK0LeK8lNnAxjtTLkyEQ3RfRFct-FJbeObjQO67DarLJTESM4l4hhlc8uRlZFwCiCfw3EJZkfwS9555B83G7tkv9wIInoidoo2VPmYnUWbM_FqdnfrFqU/s16000/IMG_3124+copy.png" /></a> <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZmCYvRGB46-ctWviVv_h6pudcbXSct-KrePKWn9A-Qky6wy86MiroOktTj3Y_yrJic6JK2CNqu88Tgrst88G8asEfbHzgdatCMPJO5UMrgqNTQBRun40blYU326NNkSRwAhLcHHrUZ_g/s640/IMG_3126+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZmCYvRGB46-ctWviVv_h6pudcbXSct-KrePKWn9A-Qky6wy86MiroOktTj3Y_yrJic6JK2CNqu88Tgrst88G8asEfbHzgdatCMPJO5UMrgqNTQBRun40blYU326NNkSRwAhLcHHrUZ_g/s16000/IMG_3126+copy.png" /></a></p><p><b>Top</b><br />
While I originally conceived the top as (2) layers of plywood, I didn't think it would be strong enough. When I decided to add a vise mount I knew plywood would not work.</p><p>The reason to glue 2x4s face to face instead of edge to edge is that lumber
expands across it's width. This configuration is less stress on the joints.</p><p>
I used off cuts for a few of the bench top boards. If I were doing this again, I would not do that. It's not worth the ~$15 in savings to deal with the hassle of splices. They need additional support during glue up.<br />
<br />
I ripped 1/4" off each 2x4 for the top as the corners have a bevel, then ripped all the boards to a 3" width. <br /></p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkAlf0czp9C60lDKHDEE7O2G6lAke216HXPKvWKBPtF8iXuSC-AhelIggsCZcV9_FK8sg88euzs1RDVDANYTwHfvCY_ftOBjH2XklAxWuRp3SfRu1daiA5CvTVya38CSYnfwxlUgZB-YE/s640/IMG_3089+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkAlf0czp9C60lDKHDEE7O2G6lAke216HXPKvWKBPtF8iXuSC-AhelIggsCZcV9_FK8sg88euzs1RDVDANYTwHfvCY_ftOBjH2XklAxWuRp3SfRu1daiA5CvTVya38CSYnfwxlUgZB-YE/s16000/IMG_3089+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Original 2x4<br /></td></tr></tbody></table><p>
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV3kwGySuD5rmHjthjDBMl8e0yuMFG0QbnkcysSWjuE23iEm6I7C3Tmz3u5QZgY5Vdm1brS6ix0GyZiaE1kgYYxPYYtJqSaIXK8E71HKz9thobZo9RLqo4HKXxLGdnbFiqk6T25YrvIYA/s640/IMG_3091+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhV3kwGySuD5rmHjthjDBMl8e0yuMFG0QbnkcysSWjuE23iEm6I7C3Tmz3u5QZgY5Vdm1brS6ix0GyZiaE1kgYYxPYYtJqSaIXK8E71HKz9thobZo9RLqo4HKXxLGdnbFiqk6T25YrvIYA/s16000/IMG_3091+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Each end of the 2x4 ripped for a flat end.<br /></td></tr></tbody></table><p>
For the top, I have 4 bar clamps that are at least 5' long. I started with the 2x4s on the concrete shop floor. The floor is level, I checked that to make sure.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiphTfvPmr5tCTgkd8Mha12aA2KoggkL54REQyGeMVXgapG6CiYeTvQg4GbReYjX13vTbf5zFSRY-jBYuO23hguZjdeHtGAnYMbQRqReZnR9KDGVSaoiQblAurPDhcTp5HdDczHIYz_2Ls/s640/IMG_3134+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiphTfvPmr5tCTgkd8Mha12aA2KoggkL54REQyGeMVXgapG6CiYeTvQg4GbReYjX13vTbf5zFSRY-jBYuO23hguZjdeHtGAnYMbQRqReZnR9KDGVSaoiQblAurPDhcTp5HdDczHIYz_2Ls/s16000/IMG_3134+copy.png" /></a><br />
My first issue is that the clamps need to be centered on the ends of the boards. If the bar clamp is on top, the clamp face is offset towards the top of the 2x4 and causes the boards to buckle when tightened. While I got these 2x4s from a lumber yard they still having some bowing and twisting to them. Wood from a big box store would be even worse.<br />
<br />
With the clamp on the end, the clamp handle isn't high enough off the floor to turn.<br />
<br />
A threaded rod through the 2x4s would alleviate some of the issues. Lining up a hole shouldn't be a big problem, but I was already on the clamp path and didn't want to drill (64) holes or see a threaded rod sticking out of the table top.<br />
<br />
I then moved the table top onto the unfinished bench. The only issue there is supporting the splices, but once the boards were clamped tight enough that issue resolved itself.<br />
<br />
I spent too much time trying to get everything straight and square in a single glue up. 2x4s just aren't. After coming up with various ways to try to clamp the table in one go, I realized I should clamp it in smaller sections. This will make it more manageable and allow me try to get the boards to line up better. I don't have enough clamps for all 32 boards, but I do have enough clamps for 5 or 6 at a time. When a board was bowed, I clamped it along the length so it lines up with the others.<br />
<br />
I glued it up in (6) separate section. I made the ends even with the adjacent boards, and then clamped the bow out of any other boards. I wish I had spent a bit more time clamping down bowed boards, even only gluing (3) boards at a time. While a belt sander makes quick work of high boards, lower boards are more of a challenge. A bit more time in getting the boards flush with each other would have saved time on the back end. Getting any low spots out, even if it means the board is higher at the ends will save trouble in the end.<br />
</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiO4W_PdeIJMIYwuXZiZjZc1CnfpmuCvGZQGKPwFdqTSCSaWyHsNqkqWKjTPKwRG-E0k6DOgSyU2HDVEMnIgNRJ2JdAAZcdLCQj_AIZSpJFFYi8tHVLF_kTHBHsw9m_X0CkqyI2gVFf5vw/s640/IMG_3173+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiO4W_PdeIJMIYwuXZiZjZc1CnfpmuCvGZQGKPwFdqTSCSaWyHsNqkqWKjTPKwRG-E0k6DOgSyU2HDVEMnIgNRJ2JdAAZcdLCQj_AIZSpJFFYi8tHVLF_kTHBHsw9m_X0CkqyI2gVFf5vw/s16000/IMG_3173+copy.png" /></a> <br /></p><p></p><p></p><p></p><div class="separator" style="clear: both; text-align: center;"></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJtGipfNSvw6Abt7YoblLVKO-gEPJfknzDbJYoh6-tkC9w7BbqeZMKBQQm2uXSdpK_h9RSOFcnewYFcVAYyteqPsIr1tI5Wz4q2fE4XyJDNuIWs93joK1U_AJjI3R3262XEmO1momGHnA/s640/IMG_3206+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJtGipfNSvw6Abt7YoblLVKO-gEPJfknzDbJYoh6-tkC9w7BbqeZMKBQQm2uXSdpK_h9RSOFcnewYFcVAYyteqPsIr1tI5Wz4q2fE4XyJDNuIWs93joK1U_AJjI3R3262XEmO1momGHnA/s16000/IMG_3206+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I clamped individual sections.<br /></td></tr></tbody></table><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeig_luG4d-aBcsoPu4WCL4sPZVq_AS9ultd75qexTAu4jkemGQ1uuUVgPyrwsDKGWBy2TdSNhhIfvhCnBXYjTl8azqEC87NvQYlcUMvgB07TRDLQJmzgzZNRf6yHaYCSSc9FONQhIzFU/s640/IMG_3174+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgeig_luG4d-aBcsoPu4WCL4sPZVq_AS9ultd75qexTAu4jkemGQ1uuUVgPyrwsDKGWBy2TdSNhhIfvhCnBXYjTl8azqEC87NvQYlcUMvgB07TRDLQJmzgzZNRf6yHaYCSSc9FONQhIzFU/s16000/IMG_3174+copy.png" /></a></div><div>I marked and cut mortises for the posts into the top. I wish I hadn't
cut the mortises/tenons to extend through the top. They look a bit
rough. With blind mortises in the structure, that looked good. The top,
not so much. I used glue/sawdust to fill gaps so it's not as noticeable.
If I was doing an exposed tenon again, I could make it look better.
Freehanding wasn't the way to go.<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmrVrqkQ93qFxSJDpgUbjiHsuwg8SVd-R2SQnIFttI_FLCbyGHhrKBfC8a1MAsOaKxjSFIYy_9YnxiNPnzm74l2FQBn50Kxq3mvTqmYj9L-t3ipueLsC8o1Aay7WtgT37XYPo95uQt7sE/s640/IMG_3218+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmrVrqkQ93qFxSJDpgUbjiHsuwg8SVd-R2SQnIFttI_FLCbyGHhrKBfC8a1MAsOaKxjSFIYy_9YnxiNPnzm74l2FQBn50Kxq3mvTqmYj9L-t3ipueLsC8o1Aay7WtgT37XYPo95uQt7sE/s16000/IMG_3218+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Marking the tenon for the post.<br /></td></tr></tbody></table><p>I
used scissor jacks to position the top in place and slowly lower it
onto the posts. After a bit of hammering, the top was in place. (32)
2x4s gets heavy. The finished top weights roughly 200 pounds.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg79djp1Q0Ct2zLVah5dAFnMXDPeh-1zfWb5iIf4gRwRb7kVwoxGDK1IlW5xv_rfKvwyAuMLWTOakIRPvy_CBxNzGaIzmL2dkX9_Y3QMVBkAzGl-ogzCoSRS4TgD1TSCNM249LlNl9Gcg0/s640/IMG_3222+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg79djp1Q0Ct2zLVah5dAFnMXDPeh-1zfWb5iIf4gRwRb7kVwoxGDK1IlW5xv_rfKvwyAuMLWTOakIRPvy_CBxNzGaIzmL2dkX9_Y3QMVBkAzGl-ogzCoSRS4TgD1TSCNM249LlNl9Gcg0/s16000/IMG_3222+copy.png" /></a></p><p>I didn't think a glued up top would sag across 4', but it does. Part of
that is the twisting and shape of the boards. Some gaps couldn't be
clamped tight during glue up or would have made the top cup. </p><p>What I first thought was a result of gluing up the entire top was that the (2) opposite corners
cupped slightly. I considered cutting reliefs, before realizing the top
was bowing. While I tried to clamp any warping out of the boards during
glue up, some boards wouldn't mate quite flush.</p><p>Of course, I didn't realize what was happening until the top was in place and I realized the cupping was getting worse.<br /></p>I
clamped the top down on each end and installed cross braces and shims.
It's not perfectly level, but it's close enough for highway work. <br />
I put in supports on the short sides between posts and I ran (2) 2x4s in
the middle between drawer supports and attached it to the top. This
will keep the top straight. <p>This would have worked better installing the supports for the top before the top was in place. Next time!<br />
<br />
I used a pocket jig to attach the supports between posts, adding shims
as necessary to level out the top. The supports helped straighten out
the top. I can still spot a little bit of cupping, but most people
wouldn't notice.<br />
<br />
I used sawdust and wood glue to fill gaps around the posts. I used epoxy in smaller holes/gaps.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg3BGNOQVhfXym01dwYFLM1pnJILHdO_V11gn2saFoKGjuMeijKcpMvw2qytuGyhNt6cCCHCD4omxPnjtmKnMzKg9PIC1v9M0a5Znu6rB9mdO58jCpo6SvVZdrmga-HLqPRZiW-yfifbc/s640/IMG_3209+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhg3BGNOQVhfXym01dwYFLM1pnJILHdO_V11gn2saFoKGjuMeijKcpMvw2qytuGyhNt6cCCHCD4omxPnjtmKnMzKg9PIC1v9M0a5Znu6rB9mdO58jCpo6SvVZdrmga-HLqPRZiW-yfifbc/s16000/IMG_3209+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Prepping for final glue up.<br /></td></tr></tbody></table></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizRUiEJ91ybay6PAs5gedwOnBHJXtaRH0l8HVsITwIiSEoyVRz8ocMFyEeMZkCR0J1hC2hOEbFQFc1MnS9tg1-WqMDjhbGn9BALCkNogWlkVgsV-SOGFW11KRcHkRMDWeGz1E0TN8-meU/s640/IMG_3214+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizRUiEJ91ybay6PAs5gedwOnBHJXtaRH0l8HVsITwIiSEoyVRz8ocMFyEeMZkCR0J1hC2hOEbFQFc1MnS9tg1-WqMDjhbGn9BALCkNogWlkVgsV-SOGFW11KRcHkRMDWeGz1E0TN8-meU/s16000/IMG_3214+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">A belt sander helped flatten the top.<br /></td></tr></tbody></table><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX50ZuhAn4S9Sypm_sSi3k5FkQpBnwYNTRR6R1ytYnNY6XrBQzaYGICF3ojxltGqs09cwUcT2xBmPeeDGrKg8ZZVafrTjwymPXl1RtbF4dzZ82pHvkRhkRkI2f8tJb3Hs-ICV8kuye_7w/s640/IMG_3337+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX50ZuhAn4S9Sypm_sSi3k5FkQpBnwYNTRR6R1ytYnNY6XrBQzaYGICF3ojxltGqs09cwUcT2xBmPeeDGrKg8ZZVafrTjwymPXl1RtbF4dzZ82pHvkRhkRkI2f8tJb3Hs-ICV8kuye_7w/s16000/IMG_3337+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Epoxy filled any gaps. I used glue/sawdust for larger gaps but thin gaps got expoy.<br /></td></tr></tbody></table><p> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPgcHV_s8XfxuUMwxdE3xcROSy4sCgLNp01PzPvAkAQXYrVuXIzY206PCHa1Cvxw5vS-qmR9MYBcDF2yIbgMctSronKeRTXrIGQ3oRfz8Vad9kFLif049uyIQcDn8FCWlD5XQYJaK0LHQ/s640/IMG_3334+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPgcHV_s8XfxuUMwxdE3xcROSy4sCgLNp01PzPvAkAQXYrVuXIzY206PCHa1Cvxw5vS-qmR9MYBcDF2yIbgMctSronKeRTXrIGQ3oRfz8Vad9kFLif049uyIQcDn8FCWlD5XQYJaK0LHQ/s16000/IMG_3334+copy.png" /></a><br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXXVw9XwodB-5C6FlKih3grahOXQTdW36JjT4BrTAHG_PD5K0O3jU01VWDFrBmo2xGcOvy5QPVRvAnbwPc9i11hngW6CThU8jmdtGfra-6-60TvQ8rMBKda35knUBxJu8jTpQrJ39Pvd8/s640/IMG_3338+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXXVw9XwodB-5C6FlKih3grahOXQTdW36JjT4BrTAHG_PD5K0O3jU01VWDFrBmo2xGcOvy5QPVRvAnbwPc9i11hngW6CThU8jmdtGfra-6-60TvQ8rMBKda35knUBxJu8jTpQrJ39Pvd8/s16000/IMG_3338+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Touch up with epoxy.<br /></td></tr></tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKyWvD51q2FDD3c7yYr_teHCpjzfQ-ToVENYFE-RhgceCgklZAqvhw0_wuzviu8fazilhw7-zCBf4Hdg0-RasZa99fPcqaQ7SPItWRHUaFY18rP-zFVu1fw95UI5Exe6Xu7H7K_SMDUzA/s640/IMG_3339+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKyWvD51q2FDD3c7yYr_teHCpjzfQ-ToVENYFE-RhgceCgklZAqvhw0_wuzviu8fazilhw7-zCBf4Hdg0-RasZa99fPcqaQ7SPItWRHUaFY18rP-zFVu1fw95UI5Exe6Xu7H7K_SMDUzA/s16000/IMG_3339+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">The belt sander got the boards flat/even.<br /></td></tr></tbody></table><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSajC5FoT4eLUyg08L668gCDp9GcRXjK8kkj2baURWej44C2CFS-8LI91uXZdRusCDM8DXKzjy1bTraNJgiqAQVOrFxw_tj66ZfwNQC4pWVcAiwt8NoPTpSjYnMTe1tEUAgE706VLB4fk/s640/IMG_3426+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSajC5FoT4eLUyg08L668gCDp9GcRXjK8kkj2baURWej44C2CFS-8LI91uXZdRusCDM8DXKzjy1bTraNJgiqAQVOrFxw_tj66ZfwNQC4pWVcAiwt8NoPTpSjYnMTe1tEUAgE706VLB4fk/s16000/IMG_3426+copy.png" /></a> <br /></p><p>A belt sander knocked the top down to nearly smooth. A belt sander creates a lot of dust, EVERYWHERE. I made more work for myself than I needed. I should have made sure I made the boards flush during glue up.</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_69p6ZEBCwjmzn1df14Dp_svSsEjZkUfpLagrFPxAnTfq2KzbFPIvw3VhyCr0HL-HzYzlOyLZ5fMmpH_N1kbhWf76jwYVtejTMIJwgyFFk0rKx0-Ni0uSLnSIKGm7PRPtK1kEGK4r0Kc/s640/IMG_3340+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_69p6ZEBCwjmzn1df14Dp_svSsEjZkUfpLagrFPxAnTfq2KzbFPIvw3VhyCr0HL-HzYzlOyLZ5fMmpH_N1kbhWf76jwYVtejTMIJwgyFFk0rKx0-Ni0uSLnSIKGm7PRPtK1kEGK4r0Kc/s16000/IMG_3340+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">I put the first set of holes in the wrong location. Used a dowel to fill.<br /></td></tr></tbody></table><p>I drilled 4 holes for my future bench dog set up. I debated on
whether I wanted to drill holes into my just finished table top. I
decided I did, then proceed to drill four holes in the wrong spot. I
filled the holes with 1" wood dowels that were the perfect size, filed,
sanded, and marked it up as a lesson learned.<br /> <br />
<b>Drawers</b><br />
Five drawers total were installed. Three on on side and two on the
other. The vise mount will take up one bay. I plan to go back and add a
plywood shelf in the bay below the vice mount. It's dead space and that
would add a bit of function.<br />
<br />
I had ball bearing slides I picked up on sale a few years ago. I hadn't
measured them, and they ended up being 26" long. They are made for
computer/server racks, but are heavy duty. The depth I have for both
drawers combined is only ~43".<br />
Luckily Amazon has 16" ball bearing slides that are the exact length
needed. The slides will butt, mounted to the 2x4 support attached to the
top.<br />
</p><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto;"><tbody><tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK_h0WYT0h8pgFPeywi9tniGJZ5SxQA237gOGsN4NTROVM7hGJPwCcbQcXoTBDh2oI3GkHPQIwVnVRDpeOswnrALOneTnz6JU0Rk_QGbEWiMGrG8-UODp0v0YDRUFV8HVGSxYEufQEGQ8/s640/IMG_3260+copy.png" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK_h0WYT0h8pgFPeywi9tniGJZ5SxQA237gOGsN4NTROVM7hGJPwCcbQcXoTBDh2oI3GkHPQIwVnVRDpeOswnrALOneTnz6JU0Rk_QGbEWiMGrG8-UODp0v0YDRUFV8HVGSxYEufQEGQ8/s16000/IMG_3260+copy.png" /></a></td></tr><tr><td class="tr-caption" style="text-align: center;">Drawer slide.<br /></td></tr></tbody></table><p>
The drawers are 3/4" plywood with a 3/4" groove in the sides and back for the bottom of the drawer.<br />
<br />
When installing the slides, I mounted slides to the drawer, then fit the
slide receiver to those slides and dry fit. I pushed one side of the
drawer/slide tight against the support on one side and shimmed the
other side as needed. With shims in place, I used washers to match the
shims. There isn't much wiggle room with ball bearing slides.</p><p>The slides are installed with wood screws.<br />
<br />
I did have to enlarge holes in the receiver slide and create an access
hole to install screws from inside of the track for the computer rack
slides.<br />
<br />
Be sure to measure your drawers during the dry fit and make sure they are square.<br /></p><div>
Also, be sure to account for hardware in your measurements. For my shorter drawers I forgot. <br />I
had to cut them apart and piece them back together. They fit perfect in
the opening without hardware, but hardware is important.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfOkOMxDbook9EcwTcvrMe-I-rhyptZae_kvGXA8Sz90rkqcfZzkBTkNF99c8dn-1OJEpY9MxSQ_MKm3SchILigmvTfcdKUSWLHGdEIyQs27Ki64Syhv2DRFD98j4riAxsqpw9KTCq-ZQ/s640/IMG_3259+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfOkOMxDbook9EcwTcvrMe-I-rhyptZae_kvGXA8Sz90rkqcfZzkBTkNF99c8dn-1OJEpY9MxSQ_MKm3SchILigmvTfcdKUSWLHGdEIyQs27Ki64Syhv2DRFD98j4riAxsqpw9KTCq-ZQ/s16000/IMG_3259+copy.png" /></a></div><div></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkSIyQg-S6m20QtcYCVGMj-HHg5odqrpYrI3iGT6OK3peNTMhpsPkD71Qk3dJeSjXWj7kFWeVQ8HZQ0Q-hLsf4WG9C22Nx64hSXj2XhY5bFnevvxsBiTeBs1DlFNgZ5-dLkVkW0b7eUeA/s640/IMG_3279+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkSIyQg-S6m20QtcYCVGMj-HHg5odqrpYrI3iGT6OK3peNTMhpsPkD71Qk3dJeSjXWj7kFWeVQ8HZQ0Q-hLsf4WG9C22Nx64hSXj2XhY5bFnevvxsBiTeBs1DlFNgZ5-dLkVkW0b7eUeA/s16000/IMG_3279+copy.png" /></a></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLA1zxkAeyEof4TeCW0VVyWhhv2a81n_pqdYZQoP4yvjyWiQzlUL6cXFJNqRpmdFyXTlTfXe_pDhNTH_jA39BOukNMkeu3N_qrC8Zhx_orvS56YbRWfPIhcrkrzCM8EdK3GGCzEaCRkCY/s640/IMG_3280+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiLA1zxkAeyEof4TeCW0VVyWhhv2a81n_pqdYZQoP4yvjyWiQzlUL6cXFJNqRpmdFyXTlTfXe_pDhNTH_jA39BOukNMkeu3N_qrC8Zhx_orvS56YbRWfPIhcrkrzCM8EdK3GGCzEaCRkCY/s16000/IMG_3280+copy.png" /></a> </div><div> </div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg39hRk-twq3KhqsZYKU3En1WeBGmSpxscDfe67AQx5qB2jR_HCVbXXrMYGD9gs3gqwluZUpSlqRScjwndWi69aFJe1iz6pkyIKgwudm09XnsTgu_apRg7iNTfp9kNpxJ8R3kj22Xz_01Q/s640/IMG_3292+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg39hRk-twq3KhqsZYKU3En1WeBGmSpxscDfe67AQx5qB2jR_HCVbXXrMYGD9gs3gqwluZUpSlqRScjwndWi69aFJe1iz6pkyIKgwudm09XnsTgu_apRg7iNTfp9kNpxJ8R3kj22Xz_01Q/s16000/IMG_3292+copy.png" /></a></div><div> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizK7alm4K7SXIzN5v5wZ49mYnFtC2K383vGPx3FsQRstOJ815LBaskHqsG-6l_nfT-bp3j0TfPO7q7_X5qVqVplYCkuWSoMkNo9NdkoQrM55dXLFITUAqNZbpoPEDHiED6dYir9nICxtk/s640/IMG_3294+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizK7alm4K7SXIzN5v5wZ49mYnFtC2K383vGPx3FsQRstOJ815LBaskHqsG-6l_nfT-bp3j0TfPO7q7_X5qVqVplYCkuWSoMkNo9NdkoQrM55dXLFITUAqNZbpoPEDHiED6dYir9nICxtk/s16000/IMG_3294+copy.png" /></a></div><div> </div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqsg3S5KW_Ekf1skofs3ML3VuePjrelfstthlDlwjpleMvPKbrQuqsSu5LTo3tuQhuuZ324S4vpwQQ4JMDxQZJYEq-Qg3bhDDzf-Tzw6feF_E3xabrMM1B0b1lz15ZqEmLFDKFVEk2EPs/s640/IMG_3302+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqsg3S5KW_Ekf1skofs3ML3VuePjrelfstthlDlwjpleMvPKbrQuqsSu5LTo3tuQhuuZ324S4vpwQQ4JMDxQZJYEq-Qg3bhDDzf-Tzw6feF_E3xabrMM1B0b1lz15ZqEmLFDKFVEk2EPs/s16000/IMG_3302+copy.png" /></a>I
recessed the hardware in the drawer faces to gain more hardware
clearance. When it came time to attach drawer faces I quickly began
rethinking that idea. Cutting a recess wasn't too difficult luckily, but
it is an extra step that could lead to a mistake. It's also not worth
the effort to gain 1/2" extra space.<br /></div><div><br /></div><div>I cut
the faces last, using a cardboard template cut to fit the opening to ensure tight
clearances for the recessed faces. The drawer face overlapping the
structure makes the fit a lot easier, but I wanted a certain look.</div><div>Once
the faces were cut, I used a dab of hot glue to position the face in
place before drilling the holes. I needed the drawer to fit perfectly in
the opening. Once the holes were drilled I removed the hot glue and
installed the faces. I used a block sander to fine tune a few edges on
the faces.I used pocket holes to attach the drawer face to the drawer.<br /></div><div><br /></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjygUzhUVuRxxWibWr_SY6QIClY0UfIgkm2NXrLdpkRDavgIwmLY8KsP-TcKxgzGuwqgLMTtEHpy79LPSkEVeUy3usyir2me_53AMUH1iyWttOPpAfiap4GCTz9jYL-2VYBg646ZVIQw80/s640/IMG_3324+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjygUzhUVuRxxWibWr_SY6QIClY0UfIgkm2NXrLdpkRDavgIwmLY8KsP-TcKxgzGuwqgLMTtEHpy79LPSkEVeUy3usyir2me_53AMUH1iyWttOPpAfiap4GCTz9jYL-2VYBg646ZVIQw80/s16000/IMG_3324+copy.png" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizXnpwzVNQYiYjPjmHakP5VV-F8P8qxFa1TnCJgznYpBMYq7T1nSC5kQ79bmoNehWKksYldK6cIs6Wyt7eYhiqJ_VMYZo-2nadqcYZUEd3SR7Bq3uqXHHKyj6vwsxQlbI8GiUXJcr1Q1U/s640/IMG_3323+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizXnpwzVNQYiYjPjmHakP5VV-F8P8qxFa1TnCJgznYpBMYq7T1nSC5kQ79bmoNehWKksYldK6cIs6Wyt7eYhiqJ_VMYZo-2nadqcYZUEd3SR7Bq3uqXHHKyj6vwsxQlbI8GiUXJcr1Q1U/s16000/IMG_3323+copy.png" /></a></div><div>For
the drawer pulls I used 1.5" aluminum angle cut down to 1.5x.5. I
countersunk holes and recessed the handle into the top edge of the
drawer face. I wanted pulls that would be almost hidden. These came out
perfectly.</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq5ov9em_r3m7QRdp7gS0yB-_c2qsC2OsKMEX1HywJ6dmf2_ac0jRt-VVCWN3acp_fD6Pih6t78JFwbZ6OJvtpaD_tMSKSPXSdpOjWIspUQJ4zLGWXupYeZPyH-Gf79TF2jpNIHnMjyI4/s640/IMG_3312+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq5ov9em_r3m7QRdp7gS0yB-_c2qsC2OsKMEX1HywJ6dmf2_ac0jRt-VVCWN3acp_fD6Pih6t78JFwbZ6OJvtpaD_tMSKSPXSdpOjWIspUQJ4zLGWXupYeZPyH-Gf79TF2jpNIHnMjyI4/s16000/IMG_3312+copy.png" /></a> <br /></div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgn3pWZGWHtuhneaDUd-fdkQUuLvP2WVGnc5vcpdramXaj721Ns7Oo01V2DcNFUVrcHcKtelE43grKUR2AxRsc5rSd5b_ksvhu24UI6IbEcq1jGlVGZzNiVpv10_emtXAav8xSVfRVrVMs/s640/IMG_3336+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgn3pWZGWHtuhneaDUd-fdkQUuLvP2WVGnc5vcpdramXaj721Ns7Oo01V2DcNFUVrcHcKtelE43grKUR2AxRsc5rSd5b_ksvhu24UI6IbEcq1jGlVGZzNiVpv10_emtXAav8xSVfRVrVMs/s16000/IMG_3336+copy.png" /></a></div><p>
<b>Vise Mount</b><br />
The vise mount is a hitch receiver welded to 3/8" steel plate. Carriage bolts
(6) and washers go through the plate and table. I thought about
recessing the washers and bolt heads, but then I would have open space
around the head that would collect sawdust. I decided to just recess the
washer, but didn't have a forstner bit large enough.</p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWQuqy2Gvg0mvLe8GTssv8hY48jF1J2iaHrgtdjLVZK49vTX_urr47pDQ9QXWO4LytcIHbfLseOLVhVGaxpaMFbzAxIAb-rh4n87fqMPqFie3ywxMXCLa9DnZ050fc90GUsG2s6If_3Bc/s640/IMG_3435+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWQuqy2Gvg0mvLe8GTssv8hY48jF1J2iaHrgtdjLVZK49vTX_urr47pDQ9QXWO4LytcIHbfLseOLVhVGaxpaMFbzAxIAb-rh4n87fqMPqFie3ywxMXCLa9DnZ050fc90GUsG2s6If_3Bc/s16000/IMG_3435+copy.png" /></a> <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqgSov5-yA1zanJHvVOEtlMZeKyzZXu2XHHIIDEWg_fXLclhyphenhyphen8Qb6QcnU6SxLUqULZwTz-qLQ0QDhrkCMsDc1Q84jERWzLMyuwXU25v2Dz9SVMu3LyJmztzfb7CsyeG8A5T4Xd6dECLwY/s640/IMG_3434+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqgSov5-yA1zanJHvVOEtlMZeKyzZXu2XHHIIDEWg_fXLclhyphenhyphen8Qb6QcnU6SxLUqULZwTz-qLQ0QDhrkCMsDc1Q84jERWzLMyuwXU25v2Dz9SVMu3LyJmztzfb7CsyeG8A5T4Xd6dECLwY/s16000/IMG_3434+copy.png" /></a> Once I test fit the plate, I removed it so I could add paint/finish to the table.<br /></p><p>
<b>Conclusion</b><br />I clear coated the top and painted the structure
and drawers. I wanted wood grain of the top to remain visible, but the
structure is made of up different colors of wood studs and plywood.
Paint was the only way to unify it, though I did clear the plywood shelf
just so it would remain lighter.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyihm8fa937dXz6R1luvVAVy3NG23n29zlT93tiChV1AiNPtX81e5LGEQasB6mNRJei3x1AVaXY6PH15b1CJhPeXbDOjRPZaGcCr1ql1wvHn8X5P1fSGhyphenhyphenjTMCsXz80tCBk62EdjQrlWI/s640/IMG_3431+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyihm8fa937dXz6R1luvVAVy3NG23n29zlT93tiChV1AiNPtX81e5LGEQasB6mNRJei3x1AVaXY6PH15b1CJhPeXbDOjRPZaGcCr1ql1wvHn8X5P1fSGhyphenhyphenjTMCsXz80tCBk62EdjQrlWI/s16000/IMG_3431+copy.png" /></a></p><p>The top isn't as flat as I
had hoped. Without additional tools, I wish I had attached cross braces
to the underneath of the table top right after glue up. I could have put
the top down on the floor, made sure it was relatively flat and then
added cross bracing and shims as needed.</p><p>Adding the braces later
once the top was in place and already sagging wasn't as effective. I also wish I had paid
more attention to making the studs flush withe each other during glue
up. I made sure the ends were flush, but down the middle there was a
fair amount of variance. I belt sanded the table flat, but it isn't
necessarily level. I've got one corner with a slight cup that bugs me.<br /></p><p>Standing
height is absolutely perfect. Sitting height will be too once I get a
bar stool. The issue with adding drawers is that my knees are too high
and hit the long brace under the drawers. A lower stool would solve the knee issue, but then the table would be too high. The best trade off
is being higher and sitting farther back with less knee space. If I use
my shorter stool, the table is just too tall. The fix for this would be
deleting the drawers, but I'm not willing to do that. Another option is
installing the drawers below the bottom shelf, but I don't want to have
to stoop over to access the drawers.</p><p>I've also glued and cut down plywood to fit the hitch receiver that acts as a mount for a swivel light.</p><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXIuYM61Zgtc59ZfOZkLOQMskhQcCMyfnzP09ISBfeR1ppZaut2-jf_nQ-sYwfQPTO8Ma0USw8TRbwIwD9VR1r7yG9rtfo3-j6Hexi9I-jVwkGY5tPnHXFNtxMpiN_XwbZi_kM8jF9eqU/s640/IMG_3445+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXIuYM61Zgtc59ZfOZkLOQMskhQcCMyfnzP09ISBfeR1ppZaut2-jf_nQ-sYwfQPTO8Ma0USw8TRbwIwD9VR1r7yG9rtfo3-j6Hexi9I-jVwkGY5tPnHXFNtxMpiN_XwbZi_kM8jF9eqU/s16000/IMG_3445+copy.png" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw3z0H84RfIZ9ZmEtRook0zGqqRGDgYUbwMafzo-tzerTMfI38WUVI7tjuvLaeGmQp6zwkebuziNDNl6pBz6pMTnnaxT2_GVpSiBXuUB9pQcRgjKs4RjkgtPU-Xae5x4Pu1jx0E0VcXn4/s640/IMG_3446+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw3z0H84RfIZ9ZmEtRook0zGqqRGDgYUbwMafzo-tzerTMfI38WUVI7tjuvLaeGmQp6zwkebuziNDNl6pBz6pMTnnaxT2_GVpSiBXuUB9pQcRgjKs4RjkgtPU-Xae5x4Pu1jx0E0VcXn4/s16000/IMG_3446+copy.png" /></a> <br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNAAeQHu_L3IxGoNwTba9pErBSk3qLUdaa3RSeiX8Yr6eZzWcIj3rd5pkkr8fEXXa1WrO_Vl_0DezXw1hkx8lxchG3Zd4yrPIriTKlEgzOHTkS3mR3h9iIf1dphYAdXGSa8dlqlsGNGGQ/s640/IMG_3447+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNAAeQHu_L3IxGoNwTba9pErBSk3qLUdaa3RSeiX8Yr6eZzWcIj3rd5pkkr8fEXXa1WrO_Vl_0DezXw1hkx8lxchG3Zd4yrPIriTKlEgzOHTkS3mR3h9iIf1dphYAdXGSa8dlqlsGNGGQ/s16000/IMG_3447+copy.png" /></a> <br /></p><p>The
bench dogs soon became a future project. I wanted to have the how to as
part of this post, but I'm not sure when they'll get finished. The
posts are 1" aluminum rod and will be attached to a crankshaft that will
raise and lower the bench dogs via a single crank.<br /></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidurqJLPr1yg3BlQvWvxl8yvVPtporGHMZ_VYh9-lVqGF0ffFATj3UzOucojQ8yBY58zOUy_rC9u2qMcH__IdtYTFs8cQuk_pg4YJAcpIz1TUR6_0_AcK2gWAGstq2xc4QpIOFG8Tk0yg/s640/IMG_3348+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidurqJLPr1yg3BlQvWvxl8yvVPtporGHMZ_VYh9-lVqGF0ffFATj3UzOucojQ8yBY58zOUy_rC9u2qMcH__IdtYTFs8cQuk_pg4YJAcpIz1TUR6_0_AcK2gWAGstq2xc4QpIOFG8Tk0yg/s16000/IMG_3348+copy.png" /></a></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2D7bBTKnr2A6MObdfBs93p3n-fJ4aZhgDYLavUUmiFGnZdZkgdtiTokJbqT1EYydXZM5wAdXElR4ggbKcIRb-bul1gT_rDQjHsdWDqQnRk4Yq6i55RkhBqqXQYjIR3e3vpUOENOlDCZ4/s640/IMG_3341+copy.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2D7bBTKnr2A6MObdfBs93p3n-fJ4aZhgDYLavUUmiFGnZdZkgdtiTokJbqT1EYydXZM5wAdXElR4ggbKcIRb-bul1gT_rDQjHsdWDqQnRk4Yq6i55RkhBqqXQYjIR3e3vpUOENOlDCZ4/s16000/IMG_3341+copy.png" /></a> <br /></p>I
love the amount of space I have to work. It's a luxury I've never had. I
can run multiple projects simultaneously. While I have a few nitpicks,
the bench turned out nearly exactly as I wanted.</div><div></div></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxf45C8rHBe1wMxK4VRnc8de9YTvpHE6PpuD2S2aJqnM43Ej-eePKFs7Gy7wSlh1Q_JcJCMD8pCN9HQo0AogSv6I59HTG0GJz-0bWMTOlB0A9BkxvTRosK8NT6L2fbNIZbBlhrHoiinxg/s640/IMG_4162.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxf45C8rHBe1wMxK4VRnc8de9YTvpHE6PpuD2S2aJqnM43Ej-eePKFs7Gy7wSlh1Q_JcJCMD8pCN9HQo0AogSv6I59HTG0GJz-0bWMTOlB0A9BkxvTRosK8NT6L2fbNIZbBlhrHoiinxg/s16000/IMG_4162.jpg" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnN6GiaaS2XHtH3vQ377Wz9sDlRbCwR0YSSPFipDh5emPbwfVNJKN9K9nHImPB1VyJbszgxpdagy8z_JIlbChlvzZFTGbY_0k363m3xVS-heoynUbbLxJdkKJqRviIW42pwksaxTX1NNA/s640/IMG_4163.jpg" style="margin-left: 1em; 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text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEt9DtvbSb3m6CpSUzpn7wwvCV7xUrarC8YRyZajV673mEvrV1SkgudXxOUKB1jLtp9pN_kVE15H-KNzH08owIP88HO5LumQokclYOPYmFmRTPZVG8bMDQofRnAajgdKu1UgavBRGF9Kw/s640/IMG_4176.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEt9DtvbSb3m6CpSUzpn7wwvCV7xUrarC8YRyZajV673mEvrV1SkgudXxOUKB1jLtp9pN_kVE15H-KNzH08owIP88HO5LumQokclYOPYmFmRTPZVG8bMDQofRnAajgdKu1UgavBRGF9Kw/s16000/IMG_4176.jpg" /></a></div><br />WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-44380138208560436642020-03-20T02:00:00.002-04:002021-08-14T21:50:09.818-04:00Deck Design & Construction<span face=""arial" , "helvetica" , sans-serif"><b>Design & Build an Exterior Deck</b></span><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcTYW1JJGEoc4BA6gKulvTcEmJFdXBtmVb3FjNYxhgI65IplF8M_ioJ003kvbb2_FAT6Wpu3yyIlZUocXg6YoVUamxahBVmHxWd0sxQ0GHlo_TKRU3U-JLlznl6_bBP6Fm6tmZt-8rMEg/s1600/DeckBuild.png" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcTYW1JJGEoc4BA6gKulvTcEmJFdXBtmVb3FjNYxhgI65IplF8M_ioJ003kvbb2_FAT6Wpu3yyIlZUocXg6YoVUamxahBVmHxWd0sxQ0GHlo_TKRU3U-JLlznl6_bBP6Fm6tmZt-8rMEg/s640/DeckBuild.png" width="640" /></a></div>
When I first bought my house, I knew I would replace the deck sooner or later.<br />
<a name='more'></a><br />
Once I looked into it, I soon realized nothing on my current deck meets code. Everything is wrong. I planned to get rid of it anyway, but it is amazing the previous builder got every little detail wrong. I hope the homeowner did this and not a hired professional.<br />
Footings, columns, joists, bracing, railings... everything is wrong. They even put a column in front of the garage door. You can get a car through the door, but it's tricky.<br />
<br />
What's wrong with it? The "footing" is a concrete paver sitting on top of the ground. The column is not attached to the footing. It just sits on a metal base The column is not attached to the beam either. The column is undersized. The beams are undersized. The joists span too far. The railings are insufficient and are surface mounted to the deck board. Bracing is non-existent. It's attached to the house rim joist, but the house rim joist cantilevers. The deck should be independently supported.<br />
<br />
I started designing the deck years ago. I broke ground in June and finished in <strike>October</strike> <strike>December January February</strike> March. I worked most nights and many weekends, and it was a one man job every step of the way. I didn't take any prolonged breaks until December once the deck was mostly in place and usable. It's a learning process and that takes time.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Design</b></span><br />
To start with a deck design, design the deck you want in regards to size, then work back through the joist and beam size. The overall dimensions of your deck will determine the beam and joist length. Joist size and spacing governs overhangs and the spacing of beams.<br />
As far as what direction for beams, spanning across my garage door dictated my beams would be perpendicular to the house. It's more efficient to span with a joist rather than a beam. <br />
<br />
My deck is 150 square feet, consisting of an 8'x10' patio and then a 14'-3" x 4'-8" walkway. It's roughly 11'-0" off the ground. Originally the patio was smaller, but 14' is reaching the maximum joist span so the walkway was shortened and the patio lengthened. The width at 8'-0" matches the width of the existing sun room. Stairs connect the walkway and landing and additional stairs fan out from the landing to the sloping grade.<br />
<br />
The patio and walkway width is mainly due to deck boards being 8' long and trying to minimize waste.If I made it 3'-6" wide, those offcuts are just thrown out.<br />
<br />
I have a garage door under the walkway and an entrance door under the patio. I want to avoid columns in front of those doors and I can't brace back to the house as my house overhangs. If your house overhangs, the deck needs to be independently supported.<br />
<br />
I used the <a href="http://www.awc.org/pdf/codes-standards/publications/dca/AWC-DCA62012-DeckGuide-1405.pdf">Prescriptive Residential Wood Deck Construction Guide based on the 2012 International Residential Code</a> as a guide to design the deck. I like technical things like this, so I had a lot of fun determining joist and beam size.It's more stringent than my local guidelines, but I like to overbuild.<br />
<br />
I'll start breaking down the design of the patio. It's 8' x 10'. To miss having a column in front of the basement door below, I needed an overhang of 3'-4". That requires 2x10 joists spaced at 16" on center. To span the garage door also requires 2x10s. If I didn't have a 3'-4" overhang, I could have used 2x8s at the patios, but I want all the joists the same depth.<br />
That dictated a 2x10 beam size. How far the joists span relate to how far the beams can span. The beams have to support that weight.<br />
<br />
While I could have used separate columns for the end of the walkway and patio that meet, I wanted to reduce columns. <br />
<br />
The deck code beam spans state numerous times that it only applies to framing from one side only. <br />
To
calculate beam span/joist span when framing a beam from both sides, you
need to (in my case) double the joist length. The determining factor is load. This increase in load also applies to the footings.<br />
Note that since my joists are bearing on the beam, they can't
align, they need to bear on the joist directly. With an asymmetrical
deck this offset wasn't a problem. If you were
using joist hangers, you would need an offset, because you don't want to put nails back to
back.<br />
<br />
For my center beam, taking worst case scenario, I need (2)2x12s, but I want my beam depth consistent, so I'll opt for (3)3x10s.<br />
<br />
All deck posts by code must be 6x6, which accommodates up to a 14' height. Based on joist span my outside footings need to be 18"x18"x8". For the center columns the footing is 24"x24"x11".<br />
I determined the increased load based on square footage. The center beam is carrying a 150~ sf load. In the table I found a beam & joist span that equaled that.<br />
<br />
I put 3/4" spacers between the rim joist and the house so water can drain. I don't want to trap water at the house. I will also apply peel and stick flashing to the top of each beam as water can sit in the joint and cause deterioration. Any place I have a joint that could trap water, I flashed. This also occurs where the guard rail posts are attached to the rim joist.<br />
<br />
I'm using concrete piers as you don't want wood to touch
the ground. The pier also ensures lawnmowers, etc don't hit the column
so it's added protection.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Picture Framing</b></span><br />
I like the look of picture framing the deck, where a board runs perpendicular to the other boards, framing the perimeter of the deck. Wood expands too much for this to look good after a few months. I thought composite would work instead, but reviews indicate composite expands too much too. I'm planning to dowel the mitered corners to hopefully keep a tight joint.<br />
<br />
Picture framing also requires additional 2x4 blocking around the rim joist to catch a nail for the picture framing boards. You need space to nail the board into the rim joist, but you need blocking for the back nail and for the ends of the boards coming in. The most important part of the 2x4 blocking is catching the main deck boards, as the end of every board must be nailed. If the main deck boards don't reach the rim joist, and they won't with picture framing, you need added blocking to nail into.<br />
<br />
I'll use 2x4s between the outside joist and next joist, recessed so that a 2x4 is flush with the top to catch the deck boards.The bracing needs to be 16" o.c. The blocking for the picture framing will be continuous.<br />
<br />
<a href="http://www.deckmagazine.com/design-construction/decking/picture-framing-a-deck_o">Picture framing reference.</a><br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Composite or Treated Wood</b></span><br />
I
debated with composite deck or treated wood. Composite doesn't require
yearly staining, but then you hear horror stories of it warping and
sagging, plus it gets VERY hot in direct sunlight.<br />
Composite also
will fade in color. My concern was with it's durability. Granted reviews
are skewed to the negative, I ultimately decided on treated wood. I'd
save $1300 and a bucket of water sealer and a roller with an extension
would make quick work of the yearly maintenance.<br />
<br />
Another aspect of composite, is that if I did use it, I would want to
face the railing posts and add a composite fascia to the rim joist.
That's more money.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Cost</b></span><br />
I got the lumber from a lumber yard as lumber is just too wet from a big box store and thus more likely to warp and twist. At a big box store, I'll go through half the rack trying to find a straight piece of lumber.<br />
Concrete and hardware I did purchase from a big box store.<br />
<br />
Below is a list of supplies. I tried my best to keep up with nail counts, but these are estimates at best as I did buy additional nails. <br />
<br />
<div>
<b>Concrete:</b></div>
<div>
$4.69 ea. (44) <a href="https://www.lowes.com/pd/QUIKRETE-80-lb-High-Strength-Concrete-Mix/3006075">80 lbs bags concrete</a> (cheaper to get 42 as bulk pricing kicks in at that point. If you need 29 bags, it's cheaper to buy 42)<br />
$6.25 ea. (1) <a href="https://www.lowes.com/pd/Common-0-5-in-x-10-ft-Actual-0-5-in-x-10-ft-Steel-Rebar/50214511">1/2" rebar</a> x10'</div>
<div>
$14.20 ea (5) <a href="https://www.lowes.com/pd/QUIKRETE-Common-12-in-Actual-11-5-in-QUIK-TUBE-48-in-Concrete-Tube-Form/3005464">Cardboard Tube</a> 12"x48"<br />
<a href="https://www.lowes.com/pd/Grip-Rite-2-in-9-Gauge-Bright-Steel-Fluted-Masonry-Nails-1-lb/3033155">#9 2" concrete nails </a></div>
<div>
<u>Concrete Subtotal: $200</u></div>
<div>
</div>
<div>
<b>Framing:</b><br />
<div>
(7) 6x6x8 PT columns</div>
<div>
(6) 2x6x10' PT beam & joist </div>
<div>
(1) 2x8x10' PT beam
</div>
<div>
(10) 2x10x8' PT beam</div>
<div>
(1) 2x10x10 rim joist</div>
<div>
(7) 2x10x12' PT joist & beam</div>
<div>
(5) 2x10x16' PT joist</div>
<div>
(15) 2x4x8 bracing & blocking</div>
<div>
</div>
<div>
(8) 4x4x8 guard rail posts</div>
<div>
(6) 2x12x8 stair stringers - bought (3) 2x12x16 - 8' length isn't a common size.</div>
<div>
(5) 2x12x10 stair stringers - bought (3) 2x12x16 - 10' length isn't a common size.</div>
<div>
<u>Framing Subtotal: $910 </u></div>
<div>
<div>
<b>Hardware:</b></div>
<div>
(24) <a href="http://www.homedepot.com/p/Simpson-Strong-Tie-Z-MAX-Galvanized-18-Gauge-Hurricane-Tie-H2-5AZ/100275721">Joist Hold Down</a></div>
<div>
(20) <a href="https://www.homedepot.com/p/Everbilt-1-2-in-x-3-in-Steel-Hex-Head-Lag-Screw-25-Piece-per-Box-801660/204274384">Lag Screw 1/2"x3"</a></div>
<div>
(10) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-BC-ZMAX-Galvanized-Post-Base-for-6x-BC60Z/100375044">Column Post Base Anchor</a></div>
<div>
(16) <a href="https://www.homedepot.com/p/Crown-Bolt-Galvanized-1-2-in-13-x-8-in-Coarse-Thread-Carriage-Bolt-07446/202105336">Through Bolts 1/2"x8"</a><br />
(48) <a href="https://www.homedepot.com/p/Everbilt-1-2-in-13-x-6-in-Galvanized-Carriage-Bolt-25-Pack-803620/204273451">Through Bolts 1/2"x6"</a> </div>
<div>
(74) <a href="https://www.homedepot.com/p/Everbilt-1-2-in-Hot-Dipped-Galvanized-Cut-Washer-50-per-Box-807300/204284546?MERCH=REC-_-SearchPLPHorizontal1_rr-_-NA-_-204284546-_-N">Washers 1/2"</a><br />
(46) <a href="https://www.homedepot.com/p/Everbilt-5-8-in-Hot-Dipped-Galvanized-Cut-Washer-25-per-Box-807310/204284547">Washers 5/8" </a></div>
<div>
(60) <a href="https://www.homedepot.com/p/Everbilt-1-2-in-Coarse-Thread-Galvanized-Steel-Hex-Nut-50-Piece-per-Box-804070/204274106">Hex Nut 1/2" </a><br />
(10) <a href="https://www.lowes.com/pd/National-Hardware-5-16-in-x-3-in-Zinc-Plated-Coarse-Thread-J-Bolt/1000437487">5/16" threaded J bolt</a></div>
<div>
(20) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-DTT-ZMAX-Galvanized-Deck-Tension-Tie-for-2x-DTT1Z/206006177">Guard Rail Joist Angle</a><br />
(2) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-BCS-3-in-x-6-in-ZMAX-Galvanized-Double-Post-Cap-Base-BCS2-3-6Z/207134326?MERCH=REC-_-PIPHorizontal3_rr-_-205694641-_-207134326-_-N">Double Post Cap base </a><br />
(24) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-Z-MAX-18-Gauge-Galvanized-Hurricane-Tie-H2-5AZ/100275721">Joist Hurricane Ties </a><br />
(4) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-DTT-ZMAX-Galvanized-Deck-Tension-Tie-for-2x-DTT1Z/206006177">Deck Tension Tie </a><br />
(2) <a href="https://www.homedepot.com/p/Everbilt-1-2-in-x-72-in-Zinc-Threaded-Rod-801177/204276650">1/2" threaded rod 72" </a></div>
<div>
(14) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-Z-MAX-18-Gauge-Galvanized-Adjustable-Stringer-Connector-LSCZ/202092483">Stair Stringer Hanger</a><br />
(5) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-LUS-ZMAX-Galvanized-Face-Mount-Joist-Hanger-for-2x10-LUS210Z/100375106">Joist Hangers for 2x10</a><br />
(2) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-LUC-ZMAX-Galvanized-Face-Mount-Concealed-Flange-Joist-Hanger-for-2x10-LUC210Z/100506795">Concealed Joist Hangers for 2x10</a></div>
<div>
(6) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-LUS-2-in-x-6-in-Z-MAX-Galvanized-Double-Shear-Face-Mount-Joist-Hanger-LUS26Z/100375105">Joist Hangers for 2x6</a><br />
(4) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-Z-MAX-2-in-x-6-in-18-Gauge-Galvanized-Concealed-Face-Mount-Joist-Hanger-LUC26Z/100506794">Concealed Joist Hangers for 2x6</a> </div>
<div>
(612) <a href="https://www.lowes.com/pd/Grip-Rite-1-1-2-in-13-Gauge-Hot-Dipped-Galvanized-Steel-Common-Nails-1-lb/3043026">Nails 9 ga. 1.5" [(3) 1 lb box] </a><br />
(36) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-Strong-Drive-16d-x-3-1-2-in-SCN-Smooth-Shank-Connector-Nail-1-lb-16DHDG-R/206101781">Nails 16d 3.5" galvanized [(1) 1 lb box]</a><br />
(104) <a href="https://www.homedepot.com/p/Grip-Rite-10-x-3-in-10-Penny-Hot-Galvanized-Spiral-Shank-Deck-Nails-1-lb-Pack-10HGSTPD1/100119752">Nails 10d 3" threaded [(1) 5 lb boxes]</a><br />
(1) <a href="https://www.homedepot.com/p/Nashua-Tape-6-in-x-50-ft-Select-Window-and-Door-Flashing-Tape-1343003/206495170">Butyl Flashing tape, 6" wide</a><br />
(10) <a href="https://www.homedepot.com/p/Simpson-Strong-Tie-ZMAX-18-Gauge-Galvanized-Steel-Angle-A21Z/100375047">Angle Brackets </a></div>
<div>
<u>Hardware Subtotal: $650</u><br />
<b>Decking:</b><br />
150 SF 6" wide 5/4 Decking (Composite would be 1.9x Cost, Cedar 1.77x Cost)<br />
(3) <a href="https://www.homedepot.com/p/Deck-Mate-9-x-2-1-2-in-Star-Flat-Head-Wood-Deck-Screw-5-lbs-Pack-212DMT5/305418723">5 lb Pack 2 1/2" Deck screws</a> (not nails)<br />
(1) <a href="https://www.homedepot.com/p/Deck-Mate-9-x-3-in-Star-Flat-Head-Wood-Deck-Screws-1-lb-Pack-3DMT1/305418743">1 lb Pack 3" Deck screws</a> <br />
48' of <a href="http://www.tractorsupply.com/tsc/product/feedlot-panel-cattle-16-ft-l-x-50-in-h">Railing panel</a><br />
(3) <a href="https://www.lowes.com/pd/Thompson-s-WaterSeal-Signature-Series-Pre-Tinted-Autumn-Brown-Solid-Exterior-Stain-and-Sealer-Actual-Net-Contents-128-fl-oz/1000183881">Gallons of Stain/Sealer </a><br />
Deck Subtotal: $680<br />
<br />
<b>Grand Total: $2,440</b><br />
<br /></div>
</div>
<u>Tools:</u><br />
Preliminary: tape measure, pencil/paper, <a href="https://www.sketchup.com/plans-and-pricing/sketchup-free">Sketchup</a><br />
<br />
Footings: tape measure, pencil, 2x4s, framing angle, nails, spray paint, flat nose shovel, mattock, post hole diggers, angle grinder, vice, wheel barrow, bucket, rubber mallet, level, string, string level, oscillating dremel tool, corded drill, (4) 1/8" masonry bit [keep your receipts, they will break]<br />
<br />
Framing: tape measure, pencil, truck & trailer, circular saw, hand saw, corded drill, 3/8" drill bit, 5/8" forstner bit, rasp, hammer, string, string level, level<br />
<br />
Deck and Railing: tape measure, pencil, cordless drill, circular saw, jig saw, framing angle, level, die grinder/cut off wheel, welder (optional) <br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Preliminary</b></span><br />
I designed the deck in Sketchup first. This allowed me to see each connection and make sure everything fit right. First I measured the back of my house. It's crucial to start with good measurements of where the deck needs to go.<br />
<br />
With determining joist spacing and overhang, it allowed me to figure out how to maximize the design. While a 2x12 would give me the overhang I needed, it also cost more.<br />
<br />
The Sketchup model also gave me a reference so I could double check spacing, size, etc. I did reference the model often during construction.<br />
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Once the design was set I created a spreadsheet that itemized everything I needed, from the amount of concrete to the number of nails. <br />
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Localities differ, but generally speaking you will need a zoning permit for any structure. Whether you need a building permit depends on the locality. Many only require a building permit if the structure is greater than 12' in any dimension.<br />
<br />
It's likely your local planning department would issue a permit.<br />
<br />
My locality has a deck guideline that is much less stringent that what I used, the prescriptive deck code. What you use is up to you, but you do need to at least conform to local codes.<br />
<br />
While the code states you shouldn't frame joists to a beam from both sides. Allowing joists to span from opposite sides of the beam without appropriate consideration could potentially lead to a condition where beam capacity is exceeded. I factored capacity into my center beam design. Also, joists will be offset from each other, not back to back, which by that method alone may alleviate the code restriction. You wouldn't want to nail brackets back to back.<br />
<br />
There are a lot of different types of hangers. Make sure you get ones that are appropriate for your application and joist/beam/stringer size.<br />
<br />
I exchanged hardware items more than a couple times. I initially thought <a href="http://www.homedepot.com/p/Simpson-Strong-Tie-Z-MAX-2-in-x-6-in-18-Gauge-Galvanized-Light-Adjustable-U-Joist-Hanger-LSU26Z/100375313">this</a> would be my stringer hanger. It's not. Double check everything, and double check how hardware is installed before installing.<br />
<br />
When cutting boards, especially ones that are 16' long, the board needs to be fully supported so the board doesn't fall, hit you, or bind the cutting blade.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8dzTIcFfyCa3eJ_aJemAPMnspvy9vHmz3QvXe3BrCNceUDijncrcQ7Berv_-0IcWWlu7mdyC2KN-uiHiP5dPGFWUtMCVHxIDUlC7w7H5ndLJKJbrASHt3R6yAPgNKfAwUP369pTyoIzA/s1600/IMG_2025.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8dzTIcFfyCa3eJ_aJemAPMnspvy9vHmz3QvXe3BrCNceUDijncrcQ7Berv_-0IcWWlu7mdyC2KN-uiHiP5dPGFWUtMCVHxIDUlC7w7H5ndLJKJbrASHt3R6yAPgNKfAwUP369pTyoIzA/s320/IMG_2025.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The original deck.</td></tr>
</tbody></table>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSza0PuXcWFNVlIIUI6sbKLWerhFnJpHCW8wA19hG_oXF9QZWch2HZIlTtwBWN2-fEEU2nW27db-DxTDbYSbMobEjGykgTUwGyajIVzxrN53XC7eWBVmOQuDJHaIntgeGv2T1yh_5Nnfw/s1600/IMG_2027.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSza0PuXcWFNVlIIUI6sbKLWerhFnJpHCW8wA19hG_oXF9QZWch2HZIlTtwBWN2-fEEU2nW27db-DxTDbYSbMobEjGykgTUwGyajIVzxrN53XC7eWBVmOQuDJHaIntgeGv2T1yh_5Nnfw/s320/IMG_2027.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Beams should bolt directly to a column</td></tr>
</tbody></table>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzLoDTZzed_kZlTN-rBWNYm6AFUXgPSwWBhQ8KgGRxyLAzsP0Xl8kw3zqDEsFtRSxe75ZWvekaIZiywEguKA9l0IvIiw5pxUg6HqIYVwsQsdjD7w-JH9-GItDIeXVQgrTZ9FAJjvYPQrk/s1600/IMG_2028.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhzLoDTZzed_kZlTN-rBWNYm6AFUXgPSwWBhQ8KgGRxyLAzsP0Xl8kw3zqDEsFtRSxe75ZWvekaIZiywEguKA9l0IvIiw5pxUg6HqIYVwsQsdjD7w-JH9-GItDIeXVQgrTZ9FAJjvYPQrk/s320/IMG_2028.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The column should attach to the footing and the footing should<br />
be below the frost line.</td></tr>
</tbody></table>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh88__Wjfsjht8cNnv_WfkSRAGP6KxpCZlp6VyddYbKZgx-FV2TSye-Gc91rv1RjF85IVqbhPZOEi8zivvdo0sglafJT6LAZcML0kmkNK90QzaAePpRj92VN0PnEufuIOWpRoI0FwQ9MjQ/s1600/IMG_2031.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh88__Wjfsjht8cNnv_WfkSRAGP6KxpCZlp6VyddYbKZgx-FV2TSye-Gc91rv1RjF85IVqbhPZOEi8zivvdo0sglafJT6LAZcML0kmkNK90QzaAePpRj92VN0PnEufuIOWpRoI0FwQ9MjQ/s320/IMG_2031.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Surface mounted rails are not sufficient.</td></tr>
</tbody></table>
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<b></b>
<span face=""arial" , "helvetica" , sans-serif"><b>Concrete</b></span><br />
Armed with the dimensions from the Sketchup model, I laid out columns and footings. I used a 2x4 across the brick of the house for a straight edge and a 2x4 and framing angle perpendicular to the house for the column line. I used large nails stuck into the ground to stake two corners of the column, then measured the next column off the first.<br />
<br />
Then I used 2x4s and the 3-4-5 method to ensure the first two columns were 90* angles off the house.<br />
From the corner you measure 3' off one leg, 4' off the other leg, and the resulting leg of the triangle should be 5' if so you've got a square corner. If not, correct. <br />
<br />
I used a stencil cut to 5.5"x5.5" and spray paint to mark the column. While that location will disappear once I dig the column, I want to be exact as possible. While footings can be off a few inches, being off one inch in the first step can translate to two inches in the second step and it compounds.<br />
<br />
I measured the next two columns off the first two. Then I did the 3-4-5 off the first two. The patio part was in place and square. I cut stencils for the footings, 18" square and 24" square. I painted an outline with the stencil after centering it on the column outline.<br />
<br />
The last two footings were done the same way.<br />
<br />
I used rigid insulation to protect the spray paint from rain.<br />
<br />
The paint outline gives me a clear delineation of where to dig. I need to dig down 24" so the footing sits below the<a href="https://www.hammerpedia.com/frost-line-map/"> frost line</a>.<br />
It's been raining off and on during this process. The rain will soften the ground and make digging a bit easier. From research the frost line where I'm located is between 6 and 12". The footing needs to be 12" lower than that. So making the bottom of the footing 24" below the ground is a safe bet, if not going too far and I prefer to overbuild.<br />
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I used a mattock to loosen the dirt and a shovel to scoop it out.
Once I got 18" deep I used a post hole digger as the hole was too narrow
for the mattock.<br />
I forgot how long it takes to dig holes. I figured a few days. It was a week. <br />
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I cut 1/2" rebar into 20" lengths, then bent them to a right angle in a vice,
splitting it at 8/12. The rebar will help attach the pier to the
footing. Otherwise the pier would just be sitting on the footing without a connection.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7OO7jcxSSS-lItfXSP8aUY3sjFhFPU-ECPScWHQ7R26rVeFNa3rLJHTIXlb2Y4o9uDER8ZhqlIKYISuR1AKme3QvnoYwmcfT2BbNOZbvw54ZFe9sov9TRqwC73D0p4KmPLsfibqNgPl0/s1600/IMG_2196.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7OO7jcxSSS-lItfXSP8aUY3sjFhFPU-ECPScWHQ7R26rVeFNa3rLJHTIXlb2Y4o9uDER8ZhqlIKYISuR1AKme3QvnoYwmcfT2BbNOZbvw54ZFe9sov9TRqwC73D0p4KmPLsfibqNgPl0/s320/IMG_2196.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The rebar connects the footing and the pier.</td></tr>
</tbody></table>
I
mixed concrete in a wheel barrow. Three bags at a time was the max due
to size limitations. I
mixed per the instructions on the bag. The 18" footings needed 2.5 bags.
The 24" footings needed 6.1 bags, so I rounded down to an even 6. That
worked out to 3 gallons of water for 2.5 bags and 6 gallons of water for
the 6 bags. I used a plastic 1 gallon container for water. I would hold
out the last half to whole gallon from the mix and use it as needed.
You want the mix just past the point of wet enough. There should have a
slight sheen to it, but you don't want it milkshake consistency. It's
something you'll figure out as you do it.<br />
I
poured the water into the wheelbarrow first, then mixed the concrete
in. I fully mixed each bag one at a time. After you mix a couple batches
you'll get a good idea for the consistency, but it should be slightly
moist.<br />
<br />
I shoveled the concrete into the hole and then used
the shovel to level it out and tamp it down. Insert the rebar at this
point, then use a trowel to smooth the top of the concrete and work out
the air bubbles, tapping the top of the footing. Keep tapping, then tap some more. You want the air bubbles to work out.<br />
<br />
The concrete needs to cure for at least
three days before starting the piers. I managed to pour two 18" footings in a
day and one 24" footing in a day for a total of three days. Then I started adding piers after three days.<br />
<br />
I used 12" diameter cardboard forms. The forms will stick up roughly 8" past grade, 24" total height from the footing.<br />
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I wanted the tops of all piers at the same elevation. <br />
I
used concrete pavers with a piece of plywood across the holes I already
had to get an idea on how long to cut the form tubes. I measured from
the top of the footing to the top of the paver. I used plywood to raise
it if needed to achieve level.<br />
An 8' 2x4 and string with a level
were the tools used. I put the pavers where the first form would go, 8"
above the ground, then used that as a base point to determine level for
the other piers.<br />
<br />
Once the forms were cut with an
oscillating dremel tool, I cleared the top of the footing of debris/dirt
and placed the forms. Then I shoved a bit of dirt in place and tamped
it down so the forms wouldn't move around.<br />
I leveled each tube, then leveled the tubes to each other. I started at one corner and worked my way around.<br />
With
the dirt packed into place, it provides some resistance to adjust the
height of the tubes to obtain level. It also stops concrete from flowing
out the bottom of the tube.<br />
I had to trim a little bit off the
bottom of the tubes due to the footing being uneven. I used an
oscillating dremel tool, cutting the form in place.<br />
Leveling can
take a while as getting each form level, then leveling it to the other
piers, then making sure the pier itself is still level is a process.
Again, an inch off at this step compounds in each following step.<br />
Once
level was achieved all around, I added more dirt to each hole and
packed it in so the tube wouldn't shift while shoveling concrete.<br />
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I
used 2.5 bags of concrete per pier and about 2.5 gallons of water. I
used 5/16" J hooks embedded into the concrete. The future column bracket
will attach to the J hook. I tried to center the hooks in the pier,
with just a half inch sticking above the concrete. I will have to create
a recess in the bottom of the column for the bolt head. While they make
brackets that provide lift to avoid the recess all the other brackets
cost at least double.<br />
The J hooks really don't do all that much,
as I ended up nailing the brackets to the pier. You must nail the
brackets to the concrete.The J hooks do help prevent drill walk.<br />
<br />
Some brackets embed in the
concrete themselves, but I wasn't sure how exact I'd be able to get
that with embedding it in concrete. Looking back, it probably would
have been fine as concrete takes a while to cure and that would give me
time to measure and locate the bracket. These brackets are more
expensive though.<br />
I troweled the top of the pier smooth, even with
the form.Tap the form to get air bubbles out. The more air bubbles, the
less strength. Keep tapping!<br />
<br />
Not all of my piers are
exactly centered on the footing, some are off as much as 3 or 4". Maybe
there's a a better way to dig footings than marking and then digging. A
2x4 frame could help as once I started digging the markings were gone.<br />
<br />
The
concrete tubes need to be stripped from the piers after a day or two.
Just cut it down the side and pull it off. I only went a few inches
below grade.<br />
The concrete needs to dry a week for the concrete to
be cured enough to bolt to the J bolts. I eventually added nails to the
column brackets as a single J hook wasn't rigid enough. The J hooks do
help keep the brackets in place as you drill a 1/8" hole
for the masonry nails, acting as a guide. <br />
I used a 1/8" masonry bit. Clear debris frequently and keep the water flowing to cool the bit, even then you will break bits.<br />
You can drill for the nails 3 days after you pour the concrete, but let the pier cure a week before installation.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Removing the Existing Deck</b></span><br />
For many projects this will be the first step. I left my existing deck in place as long as possible, but it's time was up.<br />
To
remove the existing deck. I started with the railings which were
surface mounted. They were very easy to remove by just pushing and
pulling. They've been wobbly since day one. The screws were all rusted
which means they weren't galvanized.<br />
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I then removed the landing, the stair treads and stair stringers. I
bent all the nails over and hammered them flat to avoid any punctures.
I'm not sure any of the wood is worth keeping though I may try to
salvage the top and bottom rails of the railing. It's a steel U shape
and could make a good shelf bracket or similar.<br />
I then removed each deck board.<br />
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This
deck has columns on one side and is bolted to the house on the other. I
thought about adding temporary supports at the house side before
unbolting from the house, but instead I separated the joists and beams
from the ledger board at the house, then took down the columns.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Wood Framing</b></span><br />
The
next step is starting the wood structure. I bought the lumber from a
local yard. It's dryer wood than a big box store which means it's less
likely to warp or bow. The yard also reviews each board and discards
ones that are already warped. At a big box store the wood is wet and
everything is bowed. The downside is that the yard is only open during
the day when I'm at work, so I had to take time off.<br />
<br />
I did have to use a trailer for the lumber as many of the boards were 16' long.<br />
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The only thing the yard didn't have were 2x12x10'. That doesn't seem
to be a common size, though a 16' length is common. It was only $6 more
to get a little extra.<br />
<br />
I remeasured the center of all
of the columns. A couple of the J hooks were off a bit, only half inch
at most. That was pretty good I thought for the inexact nature of
concrete.<br />
<br />
I used a rasp to file out the bolt hole in
the base bracket. While I'd prefer the brackets to be centered on the
pier, I want the columns plumb and in line more.<br />
<br />
Since
the J hook and nut stick up past the bracket, I drilled the end of the
columns using a 5/8" forstner bit and a 3/8" drill bit to clear the nut
and bolt.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdG6GgdtsVuwmnkypjpomTOV8E_HM7MMt05SCr1F-jFykWl-h3bW7lJ5hcmI0wc75mSxMsWbFHQU1sQG3wsBzTkW2ra8BB_l6x_5lI-5g0rT1-1griHrC0usqnk6bY8WHoAC94FKXlMXY/s1600/IMG_2314.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdG6GgdtsVuwmnkypjpomTOV8E_HM7MMt05SCr1F-jFykWl-h3bW7lJ5hcmI0wc75mSxMsWbFHQU1sQG3wsBzTkW2ra8BB_l6x_5lI-5g0rT1-1griHrC0usqnk6bY8WHoAC94FKXlMXY/s320/IMG_2314.jpg" width="320" /></a></div>
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<br />
I then stained the bottom of the columns. I will stain all the structure as it provides a protective coat. The <a href="https://withwardworks.blogspot.com/2019/02/ramp-tower-and-climbing-wall-project.html">climbing wall</a> I built a year ago was out of pressure treated wood and mildew/dirt started accumulating after two weeks. I sanded it down and stained it and it looks great a year later.<br />
<br />
Plus any time you cut or drill into treated lumber, you need to retreat the cut end.<br />
<br />
The columns won't stand up on their own, to get them place I clamped 2x4s as braces in 2 directions, to ensure it's plumb and straight before nailing in the base.<br />
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With only a single bolt in the bottom of the bracket, I didn't like how much it wobbled. These brackets SHOULD be nailed.<br />
I drilled (4) 1/8" holes through the holes in the base plate into the concrete for #9 2" masonry nails using a 1/8" masonry bit
for pilot holes. I installed (4) nails into each bracket<br />
<br />
When drilling concrete, use a masonry bit. A regular bit won't work. You need to remove the bit frequently from the hole to clear debris and keep the hole/bit wet to reduce heat.<br />
Even doing this I broke three of the big box bits.<br />
With the bases nailed, the columns were a lot more sturdy. The J hook probably isn't necessary at this point with the nails. What the J-hook did do is secure the bracket so my drilled holes didn't have any walk. That is helpful as I learned with my landing later.<br />
<br />
The base bracket requires (6) 16d nails, 3 per side. Make sure they're galvanized. I set up the first beam, determined the cut line, took it down, cut it, then put it back up. This first beam will dictate the height of the other beams. I determined the height based on where I want the height of the finished deck, then subtracted deck board height and joist height. Measure the actual deck boards and joists, don't just assume as a 2x10 is actually 1.5x9.25.<br />
<br />
I want to make sure the deck is level. After the fist column is up, I'll use a string and string level to mark the lines on the other columns before cutting them. At this point the other columns are just temporarily in place.<br />
<br />
Once the top is cut, I'll notch the posts for the beam. Since one of my beams is (3) 2x's, those columns won't have a notch, the column will be cut shorter than the others for a bracket.<br />
Make sure your notch is the width of the beam so the face of the beam is flush. This will help later when bracing the beam to the column. It also ensures the beam is fully bearing on the column. With a beam on the face of a column with through bolts, you're relying on the bolts, not the column to support the deck. The deck code does not allow that.<br />
<br />
I used a circular saw to cut the beam, but the saw can't cut the entire thickness of the beam, so I cut around all 4 sides and then hand sawed the small connecting piece.<br />
<br />
For the notches, I sawed what I could with a circular saw, then hand cut the rest of the notch. Since I cut all of my lines with a circular saw the end result looks clean.<br />
<br />
For the shorter column, the bracket requires (6) 10d nails. Before attaching the bracket I cut a strip of flashing for the top of the column. This prevents water getting trapped between the beam and the column and prevents rot/deterioration.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMa16ArU0dSfDOa1OJpWEJAWuTPVRHwMiQL14wc0ciKYzGT46wMMxJmSE2ugEPTq12m3ErmqaaGt2NRWORn-fn5mLwo9s9yEdIf93qc3mAO8n5QNu5uNqlVmt-Rl-CemROQx8-O6U9cdw/s1600/IMG_2316.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMa16ArU0dSfDOa1OJpWEJAWuTPVRHwMiQL14wc0ciKYzGT46wMMxJmSE2ugEPTq12m3ErmqaaGt2NRWORn-fn5mLwo9s9yEdIf93qc3mAO8n5QNu5uNqlVmt-Rl-CemROQx8-O6U9cdw/s320/IMG_2316.jpg" width="320" /></a></div>
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<span face=""arial" , "helvetica" , sans-serif"><b>Beams</b></span><br />
My
beams are (2) 2x10s or (3) 2x10s. The beams required staggered 10d
nails at 16" on center with (2) threaded nails at each end. For the (3)
2x10 beams, that pattern occurs on both sides, nailing to the center
board.<br />
<br />
The beams should be attached with 10d nails at 16" o.c. staggered. One
top, next one 16" over at the bottom, repeating. Each end requires (2)
threaded nails (or screws). <br />
<br />
I've read it's best to
install the through bolts at a diagonal instead of one over the other to
prevent splitting, but I forgot to do that. The code shows them in
line. You'll need a 5/8" washer for the carriage bolt head as the square
head won't fit a 1/2" washer.<br />
<br />
You'll need an 8" bolt
to go through the post/beam. A 3/4" wrench will tighten the nuts. The
through bolts shouldn't be spaced farther than 5" apart vertically. Mine
are 2.5" from the top and 1.5" from the bottom.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIWRBBvxpRdFNPmN1l-76B7qRls9DybAZROD_KgBcT9yB0qmhM7UlCJMxjp-LcPVaEBk-3zMxto1y4uAHx0-U90h9X_m6DFf90INqvJlJQyYKxaO1LGEwqF_sKFbKqXCemaOBw6fi-NCQ/s1600/IMG_2324.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIWRBBvxpRdFNPmN1l-76B7qRls9DybAZROD_KgBcT9yB0qmhM7UlCJMxjp-LcPVaEBk-3zMxto1y4uAHx0-U90h9X_m6DFf90INqvJlJQyYKxaO1LGEwqF_sKFbKqXCemaOBw6fi-NCQ/s320/IMG_2324.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Flashing helps prevent water from getting trapped in<br />
the grooves between the boards.</td></tr>
</tbody></table>
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I used a 1/2" wood bit which will be a lot quicker than a regular
drill bit. Before I drilled all the way through, when just the tip of
the bit was through the back of the column, I drilled from the other
direction for a cleaner hole that reduces any tear out. <br />
<br />
For the shorter beam, the bracket to the beam requires (12) 10d nails for each bracket.<br />
<br />
The beams need to be braced in parallel back to the column, 1/2" lag screw and washer for diagonal 2x4 beam bracing.<br />
<br />
Top
of beams have flashing applied. This prevents water from being trapped
between the beams at the joints which would cause rot.<br />
<br />
When
notching the columns for the end of the walk, I notched for a 10" beam,
when my plans called for an 8" beam. The easiest fix is just buying a
2x10. I didn't want to have to buy new posts and I like the consistent
beam depth anyway.<br />
<br />
Once the beams were installed, the
end beam/columns need to be braced in parallel. If you had (3) columns
supporting a single beam, the deck code states to not brace the middle
column. I do not have that condition.<br />
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For bracing, use a 2x4 with 3" long 1/2" lag bolts and washers. One
bolt at each end centered on the beam/column.The bracing needs to be at a
45* angle to the columns/beams. I used a 3/8" drill bit as a pilot
hole.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Joists</b></span><br />
I'm using joist brackets (hurricane brackets) with the joists resting
on the beams. Using this method, blocking needs to be between the
joists along each beam. Otherwise the joists would twist.<br />
I will add bridging mid span of the walkway since
it's so long, to prevent it from feeling bouncy.<br />
I didn't use
joist brackets as it would add cost to the project. Joist brackets keep
the top of the joist even with the top of the beam. The height reduction
isn't an issue for my application.<br />
<br />
When cutting the
joists, I cut one end to square it off, as the rough lumber isn't always
square. I was able to use some of the off cuts for the joist bridging.
For the joists, I looked for the best looking joist that had the fewest
knots for the rim joist. When cutting the joists to size, I'd try to
position my cut to remove the end of the board with most knots, just to
keep the joist looking it's best. <br />
<br />
The brackets need
(10) 4d nails. That's 1.5" long so they don't poke through the joists. I
clamped the joists down when nailing and used a framing square/level.<br />
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<br />
When I eventually place the deck boards, I will notch or shim the deck boards (not the joists) as needed so deck boards will sit level. Not all joists are the same exact depth.<br />
<br />
I used the 10d 3" threaded nails for the bridging. I offset and alternated each 2x10 so that I could nail directly into the bridging 2x10. Each one requires 4 nails, (2) each side.<br />
<br />
I had a few bridges that were very short due to joists coming in to the center beam. I nailed a 3" nail all the way through or toe nailed it. <br />
<br />
I added intermediate bridging mid span of the 12' walkway to reduce flex/bounce. The 8' patio didn't have any bounce.<br />
<br />
At this point I stained the structure. It will be easier to stain now before I install the deck boards.<br />
<br />
Where the two joists butt, I centered bridging on the joint and used (2) angle brackets on each side to attach bridging and joist.<br />
<br />
The rim joists require (3) 10d nails into each perpendicular joist.<br />
<br />
For the rim joist against the house I used (2) concealed joist
brackets and (5) regular joist hanger. I clamped the rim joist into place,
with a 3/4" plywood spacer against the house.<br />
I had to mark for the concealed joist brackets, install them, then install the regular joist brackets in place.</div>
<div>
I used 1.5"
nails with 10d nails at the regular joist hangers that are toe nailed. <br />
For the bridging to the joist next to the house, I used (2) angle brackets on each bridge since I could nail directly from the back side.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Guard Rail</b></span><br />
The guard rail posts are installed next. They require (2) through bolts through the rim joist and then 2x4 blocking and brackets back to a main joist. Posts need to be strong, especially when you're eleven feet up. If your deck is higher than 30" from grade, the code requires a guard rail.<br />
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The posts require 1/2" carriage bolts/washers/nuts and a tension bracket at the post and at the blocking back to the next joist.<br />
<br />
If your post is at a corner/rim joist you wouldn't need the extra blocking/bracket at the next joist. <br />
<br />
A 2x4 nailed back to a joist isn't enough as the nails could pull out, so a tension tie with a carriage bolt is at the post and back to the main joist using 2x4 bracing.<br />
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The tension ties require 6 nails each. They can't be longer than 1.5" otherwise they would protrude through the brace. I used 3" threaded nails to attached the blocking through the joists.<br />
A 1/2" wood drill bit is needed for the bracket/bolt. <br />
<br />
I also placed all of my post blocking 1.5" below the top of the joists as I will add more 2x4 framing for the picture framed deck board edge.<br />
<br />
My one corner post is in a tough to reach spot. Neither of my drills with bits fit. I had to borrow a right angle attachment.<br />
<br />
I drilled the holes in the guard rail post first. <br />
I ran a clamp from joist to joist for the guard rail post to rest. Then I would adjust the placement and clamp it to mark where to drill holes in the joist.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh8PM7NAnIvgB4AfXYKIAeY2oly_JHLVmR28nLmG8_62hqBumhpmBsINlwz-liocceePmUS9f5PjbzWqG58K7oaNrH-kth3gh7eAiVzjt-khVhnA3z86lnkC1YitrBZ8w9yjT3W4sz1WY/s1600/IMG_2638.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh8PM7NAnIvgB4AfXYKIAeY2oly_JHLVmR28nLmG8_62hqBumhpmBsINlwz-liocceePmUS9f5PjbzWqG58K7oaNrH-kth3gh7eAiVzjt-khVhnA3z86lnkC1YitrBZ8w9yjT3W4sz1WY/s320/IMG_2638.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">I used a round over router bit for the top edges of the guard rail.<br />
It looks better and is smoother.</td></tr>
</tbody></table>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6ELFIGtAmndysExaw2KcqhRfhK5o-GfbEPQkAre3ITLtkb-OGEVjFaLGJ1Q-z7LXFt5RBUhOD0-4dy7k6KMYi8-k2p_3YeCeO0rliuEuhypAARa3fYTuBxozWtHfhNQ65U72LMPlck2s/s1600/IMG_2677.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6ELFIGtAmndysExaw2KcqhRfhK5o-GfbEPQkAre3ITLtkb-OGEVjFaLGJ1Q-z7LXFt5RBUhOD0-4dy7k6KMYi8-k2p_3YeCeO0rliuEuhypAARa3fYTuBxozWtHfhNQ65U72LMPlck2s/s320/IMG_2677.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Mitered corners provide a cleaner look.</td></tr>
</tbody></table>
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<br />
The top of the guard rail is 2x6's attached to the top of each post. A 2x4 at the top and 4" off the deck are attached to the inside face of the guard rail posts to attach the baluster. I'll discuss the rail panels later in the post.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Tension Tie</b></span><br />
While the beams are braced, my deck wasn't braced in the opposite direction. I used (2) 6' 1/2" threaded rods with a tension tie at each end. Also (4) washers and (4) nuts at each end. I did two tension ties, one on the second joist from the outside both ways.<br />
<br />
The bar extends 12" into the new deck and 5' into the joists of the house. Since the house joists are perpendicular, I added block between each joist to prevent pull. Worst case scenario, the existing joists could buckle if the deck were pulled.<br />
<br />
The rods would need to be angled down towards the deck so that water doesn't creep into your house.<br />
With my scenario, I attached the ties to a sun room that had accessible joists. I did have to drill a 1/2" hole through the joists for the threaded rod.<br />
<br />
Just hand tight, the sway in the deck was completely gone. I did tension it somewhat, as one corner of the deck was closer than 3/4" to the sun room.<br />
<br />
I ended up adding another tension tie at the other end of the deck parallel to the deck beams. There was a slight bit of sway.I did have to drill into and through my fascia panel. The tie is angled down towards the deck so water will drain away from the house.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Landing</b></span><br />
The lower landing is tricky to layout. It's basically free standing and I have to measure off the as of yet unfinished deck which is also 5'-6' higher.<br />
<br />
I built a temporary landing out of 2x4's just so I knew the size and could space footing and column locations off of that. I clamped (4) 2x4s together.<br />
<br />
I clamped vertical 2x4's to the top of the deck, marked 3'-11" down and marked it after plumbing the 2x4's and then clamped more 2x4's to the verticals and put the temporary landing in place.<br />
It sounds like a lot of work, but I need measurements off the deck and I need them lower. I will keep the temporary landing framing clamped together so I can check, footing locations, footing holes once dug, column locations, etc. I continually checked to ensure it was square.<br />
You want to use the longest 2x4s you have to strike a straight line from the deck to landing.<br />
<br />
Part of the issue with the landing is that it's on a slope. I'd prefer to normalize the footing depths, but it's a lot of effort for just a preference. I'll go 2' deep on each footing from the surface. While my other footings extended 8" above the ground I only need these to extend two inches as there is no way to hit them. They need to extend past the grade to block water from the column/bracket. With the size of the landing I don't need footings, I can just use concrete piers.<br />
<br />
Each pier took 2.5 bags of concrete. I let the piers cure (2) days before stripping the forms and (3) days before drilling the holes for the brackets. I installed the nails/brackets after a week.<br />
I didn't use J hooks this time around, which would have been nice just to hold the brackets in place to prevent walk while drilling. Without the bracket clamped down, the drill walked a bit when drilling the holes.I had to use a rasp to enlarged a few of the nail holes.<br />
<br />
I ran the piers ~2" higher than grade. The landing ended up being a bit higher than I had planned as the beams are 5.5" tall plus the height of the bracket.<br />
<br />
The columns are 6x6. The two short ones are 9" tall to account for the beam notch and the bracket. The lower columns are 20" tall.<br />
<br />
The columns must be notched for the beam. <br />
<br />
The beams will be (2) 2x6's while the joists are also 2x6s. I'm using joist brackets as I want to minimize the height of the landing. Each joist on the end will use concealed joist brackets.<br />
<br />
What I should have done to lay out the landing is cut my stair stringers first and based the landing off of them. My landing ended up being a bit larger than I intended (by a couple inches), slightly off axis, and rotated a fraction of a degree. Once the deck is done, you won't be able to tell, but my stringers had to be spaced a bit wider top to bottom since the landing was off.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Stairs</b></span><br />
If your deck needs stairs, code requires them to be at least 36" wide.<br />
Stair stringers are crucial. A good baseline for a stair is a 6" rise (height) and 12" run (length)<br />
My stairs will be 6 7/16" and 11.5" You'll have to adjust for your space. You don't want to be shorter than 5" and 10". <br />
<br />
You must use at least a 2x12 for the stringer. The stringers should be no greater than 18" apart.<br />
<br />
The height from the top of the landing framing to deck framing was 45.25".<br />
The distance from rim joist to rim joist was 79.57". Per the code, stairs with cut stringers shouldn't span more than 72", but 8" isn't going to cause the deck to implode.<br />
You don't need blocking between stringers, because they shouldn't span far enough to need it. If your stringers span longer than 6', the solution is to add an intermediate landing.<br />
<br />
I designed for 11.5" treads which would make it the width of the deck boards and provide a .5" overhang.<br />
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The risers worked out to 6 7/16". I will have 3/16" of 'play', but that's a small enough dimension to absorb.<br />
<br />
I sketched out my layout on the 2x12. Double checking dimensions and angles. The angel of the stair is 29.2. I rounded it out to 30.<br />
<br />
I use a 4' level and clamps as a guide for the circular saw as I cut each tread and riser. The cut was finished with a jig saw.<br />
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Once the first stringer was done, I traced it onto (4) others. On the fifth stringer I had cutting down to a science.<br />
<br />
My first tread is even with the deck, this allows me to use a sloped joist hanger. If your top tread was a step down you would need a lower joist rim. The only way to achieve that is to have the columns at the end of the deck and the lower rim joist attached to the column.<br />
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The bottom of the stringers are notched and will attach to the landing beam with 2x4 blocking between attached to the beam and the stringers nailed to the 2x4 blocking.<br />
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Stairs to grade would be attached to a post with a 12" concrete pier and post.<br />
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The stringers fit into place and can be used temporarily without any hardware. To attach the top of the stringer, use a stringer hanger.<br />
For the bottom, I used a 2x4 between the stringers with the 2x4 attached to the landing beam and the stringers attached to the 2x4. The stringers are notched and rest on the landing beam.<br />
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Each stair and riser is picture framed, which added a lot of additional blocking. It sure looks nice though!<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Picture Framing</b></span><br />
I always make things more complicated. I like the look of picture framing though it's recommended not to do it with treated wood as the mitered corners will eventually become uneven. That's why I initially considered composite. I'm using treated wood, but I have a plan.<br />
<br />
You need additional 2x4 running along the rim joist to attach the end of the boards. My 2x4 is 2" off the rim joist. To support that 2x4 you need 2x4 from rim joist to next joist at 16" o.c.<br />
<br />
For the stairs, I added a vertical 2x6 at each riser to catch the picture framing. A 2x4 parallel with the tread rests on the 2x6 and on an additional 2x4 at the riser end of the tread.<br />
<br />
The mitered corners of the picturing framing need to be doweled. If they are just nailed, contraction & expansion will ruin the joist. We'll see if doweling works. I ended up not doweling, and put some screws through the mitered ends.<br />
<br />
With my stairs not square I installed the 12.5" tread deck framing
first, then I cut the long section of tread to width. The miters
wont' be 45* so I put it in place and traced the miter from the short
framing onto the long framing.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Landing Stairs</b></span><br />
The landing is on a slope but I want stairs coming off all three sides. This is roughly one step on one side, two on the next, four on the one after.<br />
<br />
I also want the stairs to fan out in a five sided shape. Like I said, I like to over complicate things.<br />
<br />
I added (7) 12" tall 12" diameter piers to catch the stair stringers. I have (3) 4 tread stringers, (2) 3 tread stringers (1) 2 tread stringers and (3) 1 tread stringers. I also have diagonal stringers for my (5) sided shape, (2) 4 tread diagonals, (1) 2 tread diagonal, and (1) 1 tread diagonal.<br />
<br />
The outside (4) tread stringers are attached to a vertical 4x4 and bracket. One 4x4 is cut at the top of the tread, the other serves as a guard rail post. The rest of the stringers are attached to a 2x4 with the stringers bearing on the 2x4. A 2x6 would have been too tall, though I may should have doubled the 2x4. An angle bracket attaches the 2x4 to the pier.<br />
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My five sided stairs have a lot of angles. I started on one end and worked my way around. I would cut the first board a bit long, nail it in place and then skip the next section and attach the next board. I would then trace the miter onto the board in between.<br />
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Decking</b></span><br />
I used 5/4's treated 6" wide deck board. Two screws at each joist spaced 1" off the edge of the deck board. While many people won't notice the nails if they are spaced
uniformly, nails that are all over the place are much more noticeable.<br />
<br />
The boards were spaced with a .25" gap. I used scrap piece of MDF between the boards.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Handrail</b></span><br />
A deck with four or more risers requires a hand rail on one side. The rail should run continuously from the lowest riser to the highest riser, returning to the post on each end with brackets at 4' on center.<br />
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I don't want a handrail, so I'm not going to install one. I will have a guard rail, so if I decided I want a hand rail I could add one later.<br />
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<span face=""arial" , "helvetica" , sans-serif"><b>Rail Panels</b></span><br />
Per code, the rail panels should be sized so that a 4"x4" ball won't fit through any single opening. I initially planned to use galvanized goat paneling, which has 4x4 openings. When it came time to actually purchase the panels, no one had them in stock. I used cattle fencing which has 6"x6" openings.</div>
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I notched the to 2x4 with a 3/8" rabbet with a 1/2" total height. I did this to the bottom 2x4 as well, with the rabbet on the side against the guard rail post. The 2x4s are nailed to the face of the post.</div>
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The bottom 2x4 needs to be 4" off the deck. The top 2x4 is flush with the top of the post. A 2x6 will attach to the post and top 2x4.</div>
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I used a pneumatic cut off wheel to cut the panels to size. They are wedged into the rabbet which holds the panels still. the panels are sandwiched between the 2x4's and posts so they aren't going anywhere. If you do have any panels that aren't wedged tight, a staple from the back in the rabbet or a shim can solve that issue.<br />
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The rail panels would typically slope with the stairs, but I wanted all of the lines straight. I ended up cutting and having the panels welded at the stairs to follow the stair slope. It was a fair amount of extra work, but it looks good. After welding I sprayed the panels with galvanized paint.</div>
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</div>
<div>
</div>
<div>
<br />
<span face=""arial" , "helvetica" , sans-serif"><b>Conclusion</b></span></div>
<div>
This took 3x longer than expected which is typical for my projects. Getting my concrete piers in the right spot proved tricky, and even worse when installing piers for stairs as measurements aren't straight but angled. I don't know what I could have done better, maybe creating a string line system for reference and putting semi-permanent stakes in the ground. Good concrete bits are hard to find. I went though a lot of them.</div>
<div>
<br /></div>
<div>
Picturing framing requires so much extra wood, but I like the look. Wanting the rail panels lines to be straight also added a fair amount of time and trouble.</div>
<div>
<br /></div>
<div>
I didn't want a (1) tread riser off my landing, but the column brackets dictated I add a riser. I may could have cantilevered the beam farther on that side, just a foot would have resolved the height issue. I didn't account for the height of the column bracket which is what threw it off.<br />
<br />
I love the way the deck looks. Even though a few things are off, you can't tell it from looking. Once I was done I used a water sealer on all horizontal surfaces for added protection. I put a reminder in my phone to seal the deck again next year so I don't forget. I may be able to go two years between sealing. They way to check is to see if water pools or is absorbed by the wood.</div><div> </div><div><b>One Year Later Update</b><br /> A wood deck needs to be resealed yearly. One year later the deck boards were looking faded, but a few coats of sealer brought it right back to new.<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEio0Mak5RoAlkjixfpUAG2oiURv1X6PkYTH0a9OJlIBMn9QiLN3ywmJGgKtLAC2RSzCzp8RaYbp969hzBg46jdrB2_39jd18yhcahMBvQG5inm-etknAiea0Gd5_sfbChv6xIkqUgYTnqY/s640/IMG_5611.JPEG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEio0Mak5RoAlkjixfpUAG2oiURv1X6PkYTH0a9OJlIBMn9QiLN3ywmJGgKtLAC2RSzCzp8RaYbp969hzBg46jdrB2_39jd18yhcahMBvQG5inm-etknAiea0Gd5_sfbChv6xIkqUgYTnqY/s320/IMG_5611.JPEG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcd0XXMLx1NY-zHPRg20cxlkEeVeXDVMulww8HVlBZjlwpedZV-ZWC0R32z1JYKZ8PGMdqUtfcFNalIQA4xpjyQxKCL_vF8o0_ZYtEFsFtsRoMJge4XwZfQr4q8UJCP0EsNpub2xHfaFk/s640/IMG_5603.JPEG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcd0XXMLx1NY-zHPRg20cxlkEeVeXDVMulww8HVlBZjlwpedZV-ZWC0R32z1JYKZ8PGMdqUtfcFNalIQA4xpjyQxKCL_vF8o0_ZYtEFsFtsRoMJge4XwZfQr4q8UJCP0EsNpub2xHfaFk/s320/IMG_5603.JPEG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg80ei2Dm1oDkHDJ1uISvk0eHViVfhiADhEdLuRRMR5ijfGtD1zB_HC47p5HOFCM2nQDTEiqF7RUrOXnV64OH9pmznQJAKchkwIBdRC14PyprunZAk-fHmaIqfT5IhUQkM-wpYnr4j2Oks/s640/IMG_5602.JPEG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg80ei2Dm1oDkHDJ1uISvk0eHViVfhiADhEdLuRRMR5ijfGtD1zB_HC47p5HOFCM2nQDTEiqF7RUrOXnV64OH9pmznQJAKchkwIBdRC14PyprunZAk-fHmaIqfT5IhUQkM-wpYnr4j2Oks/s320/IMG_5602.JPEG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsAjtR6jWKFd3WJe0rWL9dzmM9y0Yy15sJGY8bR63IkZ7Oh71sl32HUyfB3TpK_wjOZ_-SKRZiRSyHPpzrFZho5-qEhQSyXGUBHEPEBDsHgRYf5LXGKsurAUqndcPK7ZwWoRtURVXo5o8/s640/IMG_5601.JPEG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsAjtR6jWKFd3WJe0rWL9dzmM9y0Yy15sJGY8bR63IkZ7Oh71sl32HUyfB3TpK_wjOZ_-SKRZiRSyHPpzrFZho5-qEhQSyXGUBHEPEBDsHgRYf5LXGKsurAUqndcPK7ZwWoRtURVXo5o8/s320/IMG_5601.JPEG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuOC4dlTtGbNWleV7fFS77YjVqaiPB-6qwj9WLEQFY1zE9F1h6aX7iZ9vbw1vA9g4Ozk6KvOydsCj4rXRRgs9dpsq30MpGxhrsoIvSX9TWD4ZuMQ0QoCCKQBpB0ZgL2dR1mUquKNzTk98/s640/IMG_5600.JPEG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuOC4dlTtGbNWleV7fFS77YjVqaiPB-6qwj9WLEQFY1zE9F1h6aX7iZ9vbw1vA9g4Ozk6KvOydsCj4rXRRgs9dpsq30MpGxhrsoIvSX9TWD4ZuMQ0QoCCKQBpB0ZgL2dR1mUquKNzTk98/s320/IMG_5600.JPEG" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsoCHSf5pAkr11nimAfagAkALSpF6auxXBFvZwKYy227pQ9ukmGejO0MvVRsSc14_iiDX6oq616f5gPbORq4L7IwfzaDX5fAKCGfPyQKGmFvg627wW9i_oMkHJlyIYg8mSWYIOopnnGek/s640/IMG_5599.JPEG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsoCHSf5pAkr11nimAfagAkALSpF6auxXBFvZwKYy227pQ9ukmGejO0MvVRsSc14_iiDX6oq616f5gPbORq4L7IwfzaDX5fAKCGfPyQKGmFvg627wW9i_oMkHJlyIYg8mSWYIOopnnGek/s320/IMG_5599.JPEG" width="320" /></a></div></div><div>While my miters were perfect a year ago, they've all separated to some degree. The reason to seal yearly is to maintain the waterproof properties.<br /></div>
WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com0tag:blogger.com,1999:blog-5852505765428063006.post-49277795982318942342019-11-29T02:00:00.000-05:002020-01-03T17:23:06.383-05:00Streaker Go-kart Project<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Go-kart Project</b></span><br />
<div class="separator" style="clear: both; text-align: center;">
<span style="font-family: "arial" , "helvetica" , sans-serif;"><b><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpYK-PRwuyz_8sp-ki8Ye6aEtjchKuq87Dc1TEEcqC6G6R-9FpBnAhaputrxw1JYNlrc1TttCmxiQcmeebhbkWAQdDkvED6Gd2WAv6BkW8DGxhKWDGfr5l-Gi3EkhyphenhyphenkI_S0K7c1Wx1AjI/s1600/IMG_2751.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpYK-PRwuyz_8sp-ki8Ye6aEtjchKuq87Dc1TEEcqC6G6R-9FpBnAhaputrxw1JYNlrc1TttCmxiQcmeebhbkWAQdDkvED6Gd2WAv6BkW8DGxhKWDGfr5l-Gi3EkhyphenhyphenkI_S0K7c1Wx1AjI/s640/IMG_2751.JPG" width="640" /></a></b></span></div>
<br />
After leaping headfirst into the world of go karts, I found an abandoned project. With a little bit of work it just might fund future karts. It looks like a Kenbar Streaker.<br />
<a name='more'></a><br />
All the parts were there, just not together. The kart had been extended 11". The work was solid though not detail oriented. It came with a Briggs & Stratton engine that while advertised as unknown, ended up not working. <br />
The tires were bald and dry rotting. The steering wheel plate was broken off, but I did get a clutch, chain, and plastic steering wheel.<br />
The length is 5'-10" with a 52" wheel base. <br />
<br />
<b>Purchasing:</b><br />
<a href="https://www.harborfreight.com/65-hp-212cc-ohv-horizontal-shaft-gas-engine-epa-60363.html">Engine 6.5hp 212cc</a> - $100<br />
5/16" x 3/4" 24 tpi bolt for output shaft - $0.18<br />
5/16" fender washer - $0.18<br />
5/16" lock washer - $0.18<br />
<a href="https://www.walmart.com/ip/HI-RUN-Stud-Super-Tire-4-10-3-50-5-2PR/39087988?athcpid=39087988&athpgid=athenaItemPage&athcgid=null&athznid=PWBAB&athieid=v0&athstid=CS020&athguid=0e9e2c8e-881-16977ae0614606&athena=true">Tires 4.1x3.5-5"</a> - $7 ea. (2)<br />
<a href="https://www.walmart.com/ip/HI-RUN-Stud-Super-Tire-4-10-3-50-4-2PR/39086195?athcpid=39086195&athpgid=athenaItemPage&athcgid=null&athznid=PWVAV&athieid=v0&athstid=CS020&athguid=81b0a5ac-550-169b4c72a9c126&athena=true">Tires 4.1x3.5-4"</a> - $7 ea. (2)<br />
<a href="https://www.lowes.com/pd/Hillman-1-2-in-x-5-8-in-Plain-Steel-Standard-SAE-Flat-Washer/3012324">Steel spacer sleeves</a> - $5 <br />
#40 Chain - $10<a href="https://www.mfgsupply.com/gomini/goministeering/goministeeringspindles/goministeeringspindles58.html"><br /></a>
<a href="https://www.bmikarts.com/Spindle-with-58-x-4-12-Bolt-Side-1_p_1364.html">Spindle 1</a> & S<a href="https://www.bmikarts.com/Spindle-with-58-x-4-12-Bolt-Side-2-_p_1365.html">pindle 2 </a>- $28<br />
<br />
<div>
<b>References:</b><br />
<a href="http://www.diygokarts.com/vb/forumdisplay.php?f=6&order=desc&page=3">DIY Go Carts forum </a><br />
<a href="http://www.hfqpdb.com/">Harbor Freight coupons</a> - don't pay more than $100 for engine<br />
<a href="https://www.bmikarts.com/">BMI Go Kart Parts</a><br />
<a href="https://www.gopowersports.com/">Go Power Sports Parts </a><br />
<a href="https://www.ombwarehouse.com/">OMB Warehouse Parts </a><br />
<a href="http://northerntool.com/">Northern Tool Parts</a><br />
<a href="https://gokartguru.com/images/Go_Kart_Drive_Line.htm">Kart Performance Estimator </a><br />
<br /></div>
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimkZ-0xp6JH4HrWAKDbHryjZMswycjmzAzVztR7QTYufKofhFjkWrAFDflEb2lKuN-kEh8q8RRqkGZybTsmWYb3ELwXfB593mOIjGlbufXvCWSbAhIJpvQbE1qfwisIEmxhKSXvQeL_Dc/s1600/57421426268__85634952-D24B-4AFF-82BF-FF6C941927EA.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimkZ-0xp6JH4HrWAKDbHryjZMswycjmzAzVztR7QTYufKofhFjkWrAFDflEb2lKuN-kEh8q8RRqkGZybTsmWYb3ELwXfB593mOIjGlbufXvCWSbAhIJpvQbE1qfwisIEmxhKSXvQeL_Dc/s320/57421426268__85634952-D24B-4AFF-82BF-FF6C941927EA.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">How I bought it.</td></tr>
</tbody></table>
<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Introduction</b></span><br />
I stumbled upon this kart after picking up three karts that had been sitting outside for a while (<a href="https://withwardworks.blogspot.com/2019/08/go-kart-restoration.html">check that out here</a>). This one needed less work so I started on it first. It seemed to be a quick job. It came with an engine that ended up not working. The gas and brake lines were cut, then had a second piece of rod band-aiding them.<br />
The frame was cut with a smaller tube inserted into the frame and welded, then another piece of steel running the length of the splice and overlapping each side of the frame.<br />
Expanded metal mesh covered the floor. The seat was plywood and foam covered in canvas.<br />
<br />
I wasn't sure how much I was going to redo. Depending on price, I would redo the gas and break lines. I left the frame, but thought about replacing the mesh with sheet metal.<br />
<br />
While it had a kill switch, there was no wire running to it. I was definitely going to remedy that.<br />
<br />
Here is the info on the kart:<br />
<br />
<div>
Engine: Briggs & Stratton 4 cycle 5 HP</div>
Model: 130202 Type 0198 04 Code 80032706<br />
<br />
It was a 1980 engine and it didn't last. Just in case you want some details on your old Briggs engine, here is an <a href="https://www.partswarehouse.com/130202-0198-99-Briggs-and-Stratton-Engine-s/209427.htm">engine diagram page</a> and an <a href="http://www.briggsandstratton.com/~/media/Files/BriggsandStratton/Engine%20Model%20Key%20Rev2-11.pdf">engine code key</a>. <br />
<br />
<br />
Rear tires: 4.1x3.5-5" (width x section height - wheel diameter)<br />
Front tires: 4.1x3.5-4"<br />
<br />
Clutch: 10 tooth<br />
Sprocket: 48 tooth (8" diameter roughly)<br />
Chain: #41 with a .5" pitch & 6.35 mm width between plates<br />
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Engine Check</b></span><br />
The first step was determining if the engine would work. It turned over, but that was all I knew. The gas in it smelled okay, but I replaced it anyway. The oil level was okay and the oil didn't look bad. I went ahead and bolted it to the cart just to keep it still. I scavenged mounting bolts from my other karts.<br />
<br />
I checked the air filter first, blowing it out with compressed air, but make sure you are blowing dirt out, not farther into the filter.<br />
Then I checked the spark plug. I grounded it to the motor and pulled cord. I could definitely see spark. When you do this, make sure you aren't touching the spark plug or the engine.<br />
<br />
<div>
If you don't see spark, remove the spark plug and hold the contact slightly away from the
motor. If you see spark the plug is bad. If not, that's an
issue I haven't had to figure out yet.</div>
<div>
<br /></div>
<div>
I checked the air mixture screw. I screwed it in, then two full turns out for the stock setting. I tried the engine and it made no sound that indicated it might crank.</div>
<div>
<br />
An engine needs air, spark, and fuel to run. I had ruled out problems with all but one. I put a teaspoon of gas in spark plug hole, replaced spark plug and pulled the cord. The engine didn't even try to crank and on the third pull it locked completely up. With putting gas in the spark plug hole, you need to replace the plug and attempt a start kind of quick.</div>
<br />
If the engine hadn't locked up and actually sounded like it might crank with gas in the intake, I would have cleaned the carburetor. Follow <a href="https://www.youtube.com/watch?v=XvHvxeiAdYQ">this example</a> or <a href="http://www.diygokarts.com/vb/showthread.php?t=10538">this example</a>. I may have done a <a href="https://www.youtube.com/watch?v=zkk48q-Stgw">carb rebuild</a>, but it didn't get to that point. With an unknown engine like this, a rebuild could end up being a waste.<br />
<div>
<br />
If you go the route of cleaning the carb, also remove tank and clean that and fuel lines, makes sure gas will flow all the way to the carb too. Make sure you clean the pick up filters for in the tank.</div>
<div>
<br />
I ended up getting the Predator 212cc engine from Harbor Freight.</div>
<br />
<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Engine Replacement</b></span><br />
You can't beat
the 212 cc Predator engine. It's a lower cost knock off of the Honda GX200 engine. It has a compression Ratio of 8.5:1, takes
fuel type: 87+ Octane. The engine oil capacity: 0.5 Quarts which is 16 ounces. Fuel capacity is .9 Gallons.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7IADh0vhRmKb33hn6L5G1rOxBijH1OJ02jDNLb3VGNUXYc0CU2kYRCO4pgTSwuQkxIQZaLfjjN2GsMmcH83luzI3aJilC5nvEcTtCVXq5QcBooT_B9C1CwULpXPHVMskvh8uJW0R3BqE/s1600/IMG_1636.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7IADh0vhRmKb33hn6L5G1rOxBijH1OJ02jDNLb3VGNUXYc0CU2kYRCO4pgTSwuQkxIQZaLfjjN2GsMmcH83luzI3aJilC5nvEcTtCVXq5QcBooT_B9C1CwULpXPHVMskvh8uJW0R3BqE/s320/IMG_1636.JPG" width="320" /></a></div>
<br />
It's a 3/4" output shaft with a 3/16" keyway, which matches the clutch that came with the project. The Predator does come with key stock. <br />
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRPcu_WN3jdLm7hrBejo-hS9WkeqtuddyVWn0SHhPb85P8fseqeH8FdcSJo26T2zeMueF6wQjzNMW9RNmeEWNuXkZK3JXPWB9IDxemaNSNXz4hCrLkDrbkVDxG3q0Vh-mr90FaQQsG6Es/s1600/IMG_1640.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="480" data-original-width="640" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRPcu_WN3jdLm7hrBejo-hS9WkeqtuddyVWn0SHhPb85P8fseqeH8FdcSJo26T2zeMueF6wQjzNMW9RNmeEWNuXkZK3JXPWB9IDxemaNSNXz4hCrLkDrbkVDxG3q0Vh-mr90FaQQsG6Es/s320/IMG_1640.JPG" width="320" /></a></div>
I read a lot of posts like <a href="http://www.diygokarts.com/vb/showthread.php?t=18571">this one </a>and <a href="http://www.diygokarts.com/vb/showpost.php?p=239043&postcount=7">this one</a> that the factory spring is insufficient with a kart throttle cable. I loosened the tension nut on the throttle and while it would move freely, it wouldn't return. I loosened it even more and it easily returned with the stock spring. It comes out of the box with the nut tightened down. Keep loosening it until
the throttle returns automatically. <br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgACit3vjS5sU2KJeEckUo9RzoIAxB2B-LMMpGQTdOmd5RzNBQ9dS4OvJjsIRLULcBmn5ETdiL2Vc3kfSec6UTTVaMRvC5iR_Eb2ukZ8MUpvj16khVeO75uOBsYxBCWg-RLdvKw-ywAdw4/s1600/IMG_1642.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="640" data-original-width="480" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgACit3vjS5sU2KJeEckUo9RzoIAxB2B-LMMpGQTdOmd5RzNBQ9dS4OvJjsIRLULcBmn5ETdiL2Vc3kfSec6UTTVaMRvC5iR_Eb2ukZ8MUpvj16khVeO75uOBsYxBCWg-RLdvKw-ywAdw4/s320/IMG_1642.JPG" width="240" /></a></div>
<br />
The Predator engine has a low oil sensor, but in a kart, just taking a corner can trip the sensor and shut down the engine. The oil sensor can be simply unplugged. It's a yellow wire coming out of the relay box that has a connection to a yellow wire going into the crank case. The wire from the relay can be
connected inline to ground with a momentary push button or toggle switch to use
as a kill switch.<br />
<br />
There is a cable clamp for the throttle cable and a cable anchor for the cable.<br />
<br />
<b>Engine Break-In:</b><br />
After mounting the engine, fill the oil
and check the level. The Predator takes 16 ounces. Give the pull start a
slow pull to make sure everything turns
over okay. Check your engine max throttle screw because the factory
sets it pretty low. I left mine all the way in. Fill the
tank with gas.<br />
<br />
To
start the engine, just turn the red knob to ON, turn on the gas valve with the
black lever, turn the grey lever to choke and pull the rope. While some
recommend a 3 hour break in, I rode the kart for about two hours and changed
the oil. <br />
I leave the choke on for just about a 10 seconds, then shut it all the way off.<br />
<br />
During my break in period, I noticed oil on my frame. Two crank shaft cover bolts were missing and two were very loose. This was the reason my oil was leaking. I searched my yard, but couldn't find the missing bolts. I tightened down the bolts I did have, filled it with oil, and ran the kart again. The screws didn't loosen, leading me to think the screws were not tightened to start with.<br />
<br />
Harbor Freight has a 90 day warranty, so I returned the engine after draining the oil and gas. They will ask you multiple times if you've drained them, and you do need to.<br />
<br />
<b>Speed Calculator:</b><br />
The question is always, how fast is my kart. Here is a speed <a href="http://www.diygokarts.com/speed-calculator.html">calculator</a>. Of course weight is a factor, but based just on gearing my kart will go a max 27. With the extra weight and the fact I have the throttle screw all the way in, I'm probably going 15 mph or so.<br />
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Here's the long math: <br />
3600 max rpm (governed 212 cc predator) / 4.8 (gear reduction for 10t and 48t)= 750<br />
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750x12" (tire diameter) x3.14 (pi for circumference)= 28260<br />
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28260/12 (inches to feet)= 2355<br />
2355/5280 (feet to miles)= 0.446<br />
.446x60 (minutes to hours)= 27 miles/hour. <br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Steering / Steering Wheel</b></span><br />
The steering wheel bracket was gone. I happened to have a round 3.5" plate and welded it to the steering shaft after sanding it down to bare metal The thickness is the same as what my other karts had.<br />
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If I hadn't had the round plate, I would have cut a 3" by 3" square, and then kept making small cuts to round it, finally filing it to be smooth. That might be more effort than it's worth but I pay attention to details.<br />
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The tire rods were obviously salvaged from something else, possibly a lawn mower. A tab was welded to the pit man arm, seemingly for these shorter tie rods. Also the spindle arms had been bent in.<br />
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<tr><td class="tr-caption" style="text-align: center;">Came with lawn mower tie rods</td></tr>
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The steering radius was much larger than a kart should be. I replaced the tie rods with some from another kart to dial the turning radius in. I ended up keeping the plate on the pitman arm as I could adjust these tie rods quite long enough. One end was rusted in place.<br />
I also ended up replacing the spindles. This changes dialed the turning radius in right where it needed to be.<br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Kill Switch</b></span><br />
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The kill switch on the kart still worked. Here are <a href="http://www.diygokarts.com/vb/showthread.php?t=10983">two</a> kill switch installation <a href="http://www.diygokarts.com/vb/showthread.php?t=35160">examples</a>. I ran a wire from the engine low oil sensor wire, which i unplugged and capped on the engine side. On the relay side, I connected 14 gauge wire from the kill switch, using the same cover. My switch is self grounding, but if your toggle switch has two blades, you would connect the wire from the relay to one, and then run a wire from the other blade to a screw on the kart.</div>
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Frame</b></span><br />
The top of the frame had been painted. The bottom half wasn't touched. I didn't worry about painting it.<br />
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I considered replacing the gas and brake rods because I just didn't like how piecemeal they were. Sure the frame looks the same way, but these were easier to fix. Ultimately I left them.<br />
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After running the kart the first day, a stress fracture occurred where the seat frame and extension reinforcement bars are welded, just in front of the engine.<br />
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I ground/sanded the area to bear metal and used a big bar clamp to pull the frame together to weld it in place.<br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Throttle & Brake Cables</b></span><br />
I didn't need any cable, but bicycle cable for the throttle is cheaper. Use kart brake cable for brakes. You don't want to cheap out on brakes.<br />
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The gas pedal stop should hit exactly at full throttle, match them up when connecting the throttle cable to the engine.<br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Clutch</b></span><br />
This project came with a clutch I hoped would work. It's a 3/4" shaft with a 3/16" keyway. This matches up to the Predator engine perfectly.<br />
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The engine comes with keystock, though I had to shorten to 1" for my clutch. If you need keystock, try a local welding shop.<br />
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The bolt for the output shaft 5/16-24, 1.5" long for output shaft of engine. My clutch hangs off the output shaft just a bit to line up with the sprocket, otherwise get a 3/4" bolt. Also get a lock washer and fender washer in either case.<br />
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Oil the clutch bushing before you install it.<br />
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The keyway is the slot on the shaft/clutch. The locking part is the key. A piece of 3/16"" keystock is what's typically used. It's just square steel rod that is
cut to desired length. <br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Sprockets & Chain</b></span><br />
I cleaned the chain then soaked it in motor oil so the oil could penetrate all the rollers.<br />
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Allow between 1/4 inch and 3/8 inch flex for proper adjustment, if you
have more than 1/2" flex it needs to be adjusted. Loosen the engine
mount bolts and slide the engine to reduce slack, or add washers to the bolts to lift
the engine.<br />
Adding two links made it too loose, but adding only one was too tight. I needed a half link, but didn't have one on hand.<br />
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My engine was already 1/2" away from the seat, so I added spacers to lift it up. I had frame bolt washers from an old Nissan pickup truck. That raised the engine just enough.<br />
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I had #41 chain that ended up being two links short. I bought #40 chain, mixing up what I had but #40 still works. I used this <a href="https://cutpriceracing.com.au/store/Page17/">chain guide</a> to make sure the two could interchange. I pressed out the chain studs with a punch and nut. When installing the master link, the opening should point towards the back of the kart.<br />
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<b>Gearing:</b><br />
My gearing is 4.8:1. Commonly recommended is 6:1 for a fun kart. I wasn't going to change the ratio. While the kart can be slow to take off, it isn't terrible. Though inclines can be a problem. I wouldn't recommend any shorter gearing.<br />
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Clutch: 10 tooth<br />
Sprocket: 48 tooth (8" diameter roughly) <br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Brakes</b></span><br />
The band brakes were in good shape.<br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Wheels & Tires</b></span><br />
The front wheels weren't wide enough for the spindle. While the spindle was threaded, it wasn't threaded far enough. Instead of adding a bunch of washers, I added a steel spacer sleeve. I used 3/4" EMT conduit, which I had on hand and was the perfect size. I added washers, just to protect the wheel from the spacer.<br />
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Rear tires: 4.1x3.5-5" (width x section height - wheel diameter)<br />
Front tires: 4.1x3.5-4"<br />
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I replaced the tires with studded tires, what came with the kart was bald. <br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Seat</b></span><br />
I wanted to upgrade the seat so it didn't look like a quick and dirty job, which is exactly what it was. After riding it, the foam is not enough. This seat needs a lot more padding when bouncing around.<br />
I recovered it and discovered upon tear down, towels were the only padding in the seat. I already had 2" upholstery foam from another project. I spray glued the foam to the existing plywood backer, then wrapped it in fabric. I used polyester curtains. I stapled the top of the material to the back of the plywood first, then pulled it tight and stapled it to the bottom. Then I did the sides. The corners I pulled tight trying to remove wrinkles or fold over the excess.<br />
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<span style="font-family: "arial" , "helvetica" , sans-serif;"><b>Conclusion</b></span><br />
I bought this kart to fix and sell to fund my other three karts. The engine locking up hurt the profit margin, but I knew it was an unknown. All in all, the project wasn't too bad. I had fun fixing the kart.WardWorkshttp://www.blogger.com/profile/03208414399722467241noreply@blogger.com1