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And spirally, too. This weeks job. About a third of the way there at this point.Here's the parts as shipped.I had to quickly cobble together some sort of work stands, so I made these from a scrapped reel holder and some spare parts I had laying around.Next I had to make a tread jig. Found a piece of 4" sch 40 and came up with this contraption. If I didn't have to make all these jigs I'd be done with the stair by now, but now I've got them for the next one. Any body need a spiral stair?   Next step layout the risers and mark the pipe.Trim, clean, and de-burr the treadsjust a sec. more coming.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Like just about everything else in life, start at the bottom......and work your way upAll the treads are tacked on.This view is from the bottom. I put the base plate on and use another piece of pipe with a matching base plate so I can leave room for the stair to rotate a full 360* without any interference between the bottom tread and the stand. Kind of funky looking from this angle, huh?More coming real soon.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Last pic looks like a giant auger.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Haha yeah it does, That seems like a pretty cool project.Is this gonna be powdercoated or painted?Is it for a house or commercial?Nice clean looking shop also!Beer is proof that god loves us and wants us to be happy!
Reply:looking good where did you get the kit
Reply:ThanksTo Spark it; I think it's a cool project,too. I'd be happy if I could stay busy just selling spiral stairs and gates. It's good work that doesn't tend to drag on like 800' of aluminum handrail would.(I was never so ready to be done by the end of that job)This one's getting painted satin black. I really push powder coat but this customer has tried to shave every penny on this job, and being an inside stair the paint should hold up decently. I understand the need to be prudent with money but the difference in price was less than $300.00  The difference in quality is well worth that for the durability of p-coat.The shop is so small it has to stay clean. I'm sure I'll outgrow it in a year or so. I've already been keeping a lookout for vacant facilities.to Ed;The material came from my local steel supplier, it's not a kit. 3-1/2" sch 40 pipe for the center pole, 3/4" sch 40 pipe for the handrail, 1/2 h.r. solid round bar for  pickets, 1/4"x 8"x8" base plate, 1/8" smooth plate for the treads and landing, sheared and broke to my specs by the steel yard. 2"x2"x3/16" angle to stiffen the edge of the landing with holes punched for lagging to the face of the band for mounting, and 1/4"x2" h.r. flat bar to stiffen the center of the landing.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:good stuff, keep the pics coming.
Reply:Thanks, is that Homers butt? Eww.Here you go.Get her on the bubble any way you look a t it.So the pickets that connect one tread to the next can go on.Keep checking level all the way up and add some temporary bracing.Do you feel like you're watching batman reruns, get on at the lower left and go clockwise as you go up.Looks like the auger from hell today. There's 1001ways to really hurt yourself on these things, be careful.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:After the pickets were attached I welded up the treads to the pipe. Sorry about the crappy phone pics, if I used a good camera you see how bad my s**t really is. Sorry about not having the dime in there, I didn't have any change, I 'll try to  remember my weld gauges tomorrow, Oh and I don't have a clue what my settings were. It's the powcon with unimix and .035 ER 70 S6 running at enough amps to burn it in good and enough wire speed to give that sweet powcon slow buzz.I like this one betterBut I think this'll do.By the way this one is residential, I've done a few commercial, one 6'-2" dia. is at this dirt movers office where he can look down on his lightweight galaxy, and boss 429. Luuuuuuuuke, who's yer daddy?Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Have you thought of powder coating?Good judgement comes from experience.Experience comes from bad judgement.
Reply:Outstanding work! Thanks for posting.  Very valuable info on the jigs and fixtures you made. The guys over on a Blacksmith site have a few thoughts on building these.  I especially like the one about the price, savvy advice. http://www.anvilfire.com/21centbs/spiralst.htm
Reply:Originally Posted by jtrapperHave you thought of powder coating?
Reply:Originally Posted by 200mphbusaOutstanding work! Thanks for posting.  Very valuable info on the jigs and fixtures you made. The guys over on a Blacksmith site have a few thoughts on building these.  I especially like the one about the price, savvy advice. http://www.anvilfire.com/21centbs/spiralst.htm
Reply:I finally got to work on it again today.I was busy all day Monday bidding a couple of new jobs.The hand rail is on. Next is tweak the rail a little, then bust off the temp. bracing, put the rest of the pickets in, and clean up for paint. From here on out we're coasting down hill. All the ciphering is done. It's scheduled for Friday night install, which means (yippee) I get a paycheck this week.I had to trim the landing back a little to give plenty of head room. Code is 6'-6" and I had it, but it was still a little too close for comfort, shouldn't be any trouble at all now. Pre bend the 1st 3 feet or so of the rail. I was going to make a "greenlee" style bender, but I was able to use the Hossfeld so I'll make the bender another day. It is much handier than ol' #2 for this work. Get the bend to line up pretty close to the 1st 3 pickets, or more if you feel like it.Here's my q&d spiral rail bending brace jig. The bent flat bar goes against the center pipe, then you use it as a brace to bend the rail. Once the 1st 3 pickets are tacked you just work your way up, bend, bend, bend, tack, bend, bend, bend, tack...ad infinitum. About half way up at this point.There she is. It took about 3-1/2 hours with out a helper, including having to stop and talk with a bunch of onlookers that wandered over from the country store, next door.  A little tweaking to the rail, fill in the rest of the pickets, clean up and paint, then get it out the door.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:you're almost there."Here's my q&d spiral rail bending brace jig. The bent flat bar goes against the center pipe, then you use it as a brace to bend the rail. Once the 1st 3 pickets are tacked you just work your way up, bend, bend, bend, tack, bend, bend, bend, tack...ad infinitum."Never would have figured that out on my own. Thanks.A butterfly without wings, is just an ugly bug
Reply:Aren't those poor folks gonna hit their heads walking up those stairs??Great job Ed - way to go after it! Nice job on hte dog gates too Miller Dynasty 200DXHypertherm PowerMax 45Victor OAIR CompressorLots of blacksmithing tools and other fun toys meant to creatively disfigure, reshape, manipulate and join metal.
Reply:Thanks.Hey mtncrawler if your referring to the bracing, I don't think it'd hit them in the head. I think it'd hit them in the nads. But I busted all that off this am so I could keep diggin'.I got the pickets on, and all welded up, now a little clean up with the flap wheel, then the d.a. sander. Then cut the center pole to height and cap it. Then it'll be time to huff some paint fumes. I'll get it all cleaned up today, then start painting in the am.There it is without the nad-busters. Now it's time to fill in the pickets. This is the easy way to get the spacing even. take some flat bar and mark it every 4". Since this is 1/4" thick I had to bend it to match the dia. of the stair. If I had something thinner and more flexible I'd rather have used that, then there's no bending required. Line up your marks with the existing pickets. Don't worry if the spacing isn't dead on, just pull one end till 2 of the marks are lined up. That way you're sure to keep the spacing under 4". Then take some measurements and cut your pickets. There's bound to be some variation so take your measurements in several places and average them out. You shouldn't have more than about 1/4" variation. Line up the new pickets with the marks and tack them in. You could weld them solid at this point, but I like to tack them all in 1st, then come back to weld them in case something doesn't go right, then you can still break them off if you have to.Eventually you end up with this. We're in the home stretch now boys.OK, back to work. It's not beer :30 yet.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Damn thats cool, now I want to make a stainless version. $$$
Reply:Originally Posted by app-ironworksllcThanks.Hey mtncrawler if your referring to the bracing, I don't think it'd hit them in the head. I think it'd hit them in the nads. But I busted all that off this am so I could keep diggin'.
Reply:Nice trick with the flat stock spindle gauge. I'll have to keep that trick in mind..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
Reply:You do really nice workA butterfly without wings, is just an ugly bug
Reply:Man, your kind of work is what I think of as "real" welding.  Me, I just mess around making silly little stuff mostly to amuse my friends and family.  Good thing I ain't trying to make a living at it!  I really admire your work!(Retired) Professional firefighter, amateur everything else I try to do...Oh yeah:  Go Big Red!   (You know: one of the 12 members of the Big 10 cuz we left the 10 members of the Big 12...)
Reply:Thanks for the props y'all. Here it is ready for install.Trimmed and capped the top end. And made the really cool dog leg roller for my pipe stand. Now it can rotate a full 360* and clear the handrail even after the top is trimmed. That'll make painting easier.Here she is. Thiis is the last time you'll see it naked, or nakey as my daughter says.Ta-da. I hate painting. I think from here on out I'll price a paint job the same as powder coat, then folks won't make me paint anymore.Yeah the landing does look a little streaked, but it's level with the sub-floor and will be covered by hardwood.Hintza is glad it's done, too. He's ready to go home.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:PSSST!! Dude don't look now but your steering wheel is has been moved to theother side of your truck. i think the dog done it. great looking work looksgood.
Reply:ThanksHey Hotpass he did that cuz he's a patriotic American dog, and he know which side of the street to drive on. But I told the little rascal to quit takin' my truck without asking. I used to work with a guy from New Zealand his name is Bruce you know him?Well folks today was a good day. She's in, customers are happy, and I'm paid (and happy).Locked and cocked and ready to rock!Install took 1-1/2 hours from parking to leaving. Fit perfectlyNote how well all the pickets and the center pole line up with any vertical reference points in the house. That's what I'm talkin' bout Willis!Thank you for your support.That is all.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Looks great! Are you going to do the rail around the opening also?.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
Reply:Awesome,simply awesome!
Reply:ThanksDSW- No , I'd really have liked to but one of the ways the home owner could save money was to eliminate those and build them himself out of wood rails with metal balusters. Too bad they'd have looked cool wrapping around the hole. I hope he bends them but I didn't ask. When he sends pics of the finished floors and rails I'll put them up.Last edited by app-ironworksllc; 08-07-2009 at 10:36 PM.Reason: bekawse i kant spiell fer sBrian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Another cool thing i forgot to mention he's an engineer for Volvo heavy equipment and is currently designing a pipe-laying excavator for you pipeliners.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Love it, good work man.
Reply:That is awesome.Someone needs to make an auto-darkening Predator welding helmet...complete with dreads and multiple spectra of IR vision.
Reply:That turned out really nice.  How many hours you think you got in that total, minus the painting and installation?  Again, nice work!Work HARDER, not smarter! ------------------------ Miller Bobcat 250Millermatic 251Lincoln Precision TIG 185Hypertherm PM 600Hobart 135 HandlerOxweld 400 FlameMaster
Reply:Originally Posted by Leadhead1911That turned out really nice.  How many hours you think you got in that total, minus the painting and installation?  Again, nice work!
Reply:Very nice work; you can do my stairs anytime.
Reply:Wow that is a good job with warping and bowing of the center ...is this a structural problem if say youre going 30' or so would it need hardened after welding.or put  braces every so far I guesse...???hmmm lot of torque I bet... I was watching "the kids show word world and thought about your steps... their spiral stairs eliminated that warping problem. may have caused a few more LOL... they had a chunk of pipe welded to the stair tread and they would slip over the center pipe bolt or plug weld on or whatnot ....it wouldn't be a solid smooth center pipe maybe not the look you're wanting ,and may not be to appealing or maybe pieces of pipe for the height of rise and use as filler lots of joints and potential for rust. looks like that would be the way to do it make one jig on the bench perfectly squared and keep referencing the first part I guess. (would only have one shot to screw em all up this way though) ....and the heck with all the bracing work,turning,maybe tack till the rail goes and square it all then weld... and would even be  possible to install in a couple 10,20 or 30 foot sections some welding on site for the larger ones and the rails if it didn't burn the house down may be alot faster and adjustable on site if necessary it may work but what do I know just my thoughts.Lincoln 225 Tombstone,Miller Big 20,Hobart 180,150' Argon,A/D hobart hood 22 Ton Log splitter,79 F350 dump eats 4.75 TONS and still turns cutters,grinders,And a  Hypertherm POWERMAX 30
Reply:It came out really nice!!If it isn't square, I can't even think about trying itHope he's a young dude.  Gonna regret that set of stairs when the EMS dudes have to haul his happy azz down 'em one day.Not many home designs take into account old age, and it's mobility problems"Any day above ground is a good day"http://www.farmersamm.com/
Reply:Originally Posted by app-ironworksllcThanksHey Hotpass he did that cuz he's a patriotic American dog, and he know which side of the street to drive on. But I told the little rascal to quit takin' my truck without asking. I used to work with a guy from New Zealand his name is Bruce you know him?Well folks today was a good day. She's in, customers are happy, and I'm paid (and happy).Locked and cocked and ready to rock!Install took 1-1/2 hours from parking to leaving. Fit perfectlyNote how well all the pickets and the center pole line up with any vertical reference points in the house. That's what I'm talkin' bout Willis!Thank you for your support.That is all.
Reply:Originally Posted by William McCormick JrWow very nice work there. I have been building these things for many years now. And I know just how hard they are. That is an interesting way to do the rail. It just goes to show you there is more then one way to skin a cat. I have done some two piece units for houses in Queens. Where it is very tight. The stairs were powder coated. It was rough getting it in place. When we do the rail, we usually cut a board to bend around, that bends the pipe to the exact radius of the stairs. And then we just pull the spring shaped rail apart to fit the stairs. This was for a friend of mine. He works with stainless all the time in his business. He does elevators. I told him I was running on the moving cable spools in the elevator control room, we were working in. He said I need help. Ha-ha. [i]This one was so tight. I do not even like making them this tight. But it was for my sister. So I did it. But what a pain. [i]       Sincerely,             William McCormick
Reply:amazing.http://kawispeed.com/ -moderator and tech deluxewww.myspace.com/trickortrack -cuz i have no life