Quick Scaffold

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The work around the house gradually got outta reach, so I called around about renting a scaffold.  The price was reasonable, except the couple trips to rent/return and cleanup were kind of a pita.  But worse yet, would the stucco project take a week? A month? A year? Well, it's 2.25 years later and still not done! Pic#1  Quick sketch.  345 right triangle squares it, but the most important idea is the cut list on the right.  By scale sketching, I can see what I can get out of a 10' stick, and how many needed ... in this case 8pcs.  [Wouldn't mention this except I see so many requests on here for dwgs]The steel was about $50 and the plwd+studs for the planks $20.Pic#2  Eight lengths,1.5"sq x 16ga x 10', all slightly bent, 40%off from IMS.   Cut to length.  14" chop saw on the patio, kneepads.Pic#3  Layout, clamp & tacked.  The "welding table" = old painting sawhorses.Pic#4  After tacking, weld fillets.  Settings shown.  Loox crappy - .035 flux core.  By welding one side, then the other of each "rung", then the next, and so on ... stayed square! Pic#5   X-brace center pivot.  I will not bolt thru steel tubing without sleeving it.  5/8"d with .055+/- [their idea of 16ga] will fit 1/2" bolt.Next post ... Attached Images
Reply:Pic#6  X-brace ends - 1.5"pc of 1.5x2x3/16 angle with 9/16" hole.  Ground that one face on each end so the welds wouldn't rub when X is folded flat.  Rest of welds looked better than the fillets on the ladder frame.Pic#7  1/2-13 Nuts welded to ladder frames for X-brace ends.  I like square ones.  Drilled after welding and ran a tap thru the nut. Pic#8  Oops!   Didn't fit     Notched ends to fit - didn't plan ahead!  Last pic lower left shows the problem.Pic#9  Ospho washed and set up in my handy dandy paint booth!   Those things sticking up are the feet.  They're primed, the rest is about to be.  Haven't got to topcoat yet.Pic#10  In use for soffitt / gable stucco.  Front gable was a couple feet higher so had to move big plank to top.  Seemed easier to climb with the X-braces facing out.  The planks are 1/2"cdx glued &screwed to 2x4 edges.  The one on top is 12"x7', bottom 24"x7'.  The notch at the end captures the ladder frame rung to stiffen the frames against racking.  Very handy.  Stores well outside.  Will be setting it up again this spring for another project.  Light enough for one man to "walk" it around.WARNING!  The scaffold rental place would not rent me one without the top safety rails.  His reason?  People forget they're not on a floor and step off!    I'm uncomfortable enough working that far [6'] off the ground that I was very careful.But If I use it for more than a day or so this spring, I'll make a 3 sided safety railing for it.Thanks for lookin! Attached ImagesLast edited by Fabn4Fun; 12-04-2011 at 11:45 PM.
Reply:Not bad. I've got two sets of commercial bakers scaffold some what similar to that, but it uses the straight rails and not the diagonal cross braces. I've also got 3 sections of 5' standard ladder scaffold and 4 or 5 sections of 6' walk thru scaffold.I'd find the diagonal bracing a PITA with the small bakers scaffold myself. I much prefer the flat rails, though if you have to set the rails at the top it gets a bit shaky.I do like how you went and built the platforms and notched the 2x's rather than simply using planks.Couple things you might keep in mind for spring. A nice set of leveling legs is a big help. If you have a fair amount of uneven ground they are well worth the expense. Also a decent set of locking casters that can be installed and removed is a good investment. I keep one set of casters install FT on one set of Bakers scaffolding, and have a 2nd set for the other set. I generally don't keep that set installed, since I usually use that set as my 2nd level. Also set up a set of pins at the top so you can stack 2 uprights to get a bit higher. I wouldn't mind a 1/2 height set of uprights for either rigs. The 1/2 height set would allow me to get a bit higher than 6' say for working on the eves of the roof, but could also double as your fall protection rails if working lower.You can also make your diagonal braces from 3/4" EMT conduit. Just flatten the ends with a hammer and drill thru the doubled steel and drill thru the tube at the center as is. That's pretty much what the commercial stuff is. If in doubt, go with 1" EMT. I've done fast and dirty braces ( always seems you need more braces than you'd think if you start linking sets together horizontally rather than stacking them) simply by grabbing a few 1x4's and drilling holes to match the studs on the uprights and driving a couple screws thru the braces. I wouldn't use that for stacked scaffold, but for stuff where you are only 3 or 4 foot off the ground it's a quick cheap way to get some extra braces.Almost all my scaffold was purchased used. Either picked up from CL here and there when home owners like you finished up with the project or bought from a scaffold dealer/surplus yard. Keep your eyes open and you can find some decent deals. I had to modify my 5' ladder sections to match the same width as my standard walk thru scaffold. I think the home owner bought it from some place online as it doesn't match any other scaffold sets I've measured on job sites. Something to keep in mind if you try and piece a set together.Oh if you want a super grade set of scaffold, the 24" wide ( and larger) H frames and rails like they use for pallet racking from Depot/Lowes is awesome. Very sturdy and will take a good bit of a load. Stacking is possible with the right adapters, but not common. Stuff weighs a ton however.  Lots of times if you keep your eyes open, you can pick up these when they remodel those sorts of stores free or very cheap. Wish I still had the couple sets of racks I used to have..No government ever voluntarily reduces itself in size. Government programs, once launched, never disappear. Actually, a government bureau is the nearest thing to eternal life we'll ever see on this earth! Ronald Reagan
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Reply:Nice job and very handy.
Reply:Nice job.  I have tried to purchase used scaffolding from rental agencies and it always seems they want top dollar, so I continue to watch CL. .  You have fab a good set reasonably.  Did you consider Tube versus box?  I seen a set of scaffolds today with braces as DSW mentioned.   They were plenty stout and the owner was very satisfied. If I buy a used set and they do not have leveling legs, thats an option I will have to add. Probably wheels that will adjust via a threaded rod.Last edited by geezer; 12-05-2011 at 10:33 PM.GeezerPower Mig 255C185 TIGBlue 175 MIGRanger 8 Kohler 20HP1974 5K Lincoln/Wisconsin Powered (Cherry)Victor/Harris O/AK 487 Spool Gun