Screen Wall - Build thread

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Started a thread here http://weldingweb.com/vbb/showthread.php?t=35030Now that I have my materials I started a new one for a build thread.The materials:1"x2"x.083" rectangle steel tube mandrel bent 180 degrees on 7" center line radius (the easy way) 300 of these:the work space:The jig:very simple but it works well!How it will be put together:Me grinding on my new "multi-tool" belt greinder:
Reply:Great start.  Keep us up to date.I am tired of Ketchup, I want the Gravy...
Reply:looks good! looks like your moving right along! nice simple jig, simple is good for production. keep the pics coming.millermatic 200 millermatic 150miller bluestar 2Epurox / oxweld O/A
Reply:You do some very interesting projects MA.  I enjoy seeing them and how you make them come together.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Some pics from todaywaiting for a full welda couple sets welded and ground smooth
Reply:I'd have to have some pieces in all stages so I could move around and not go nutso doing one thing over and over. Looks like you're doing that  .. Looking good so far.
Reply:i saw the notations at the beginning of the thread saying the bends are mandrel bent but why did the outside of the bend get concaved during the bend?...is that the inherent nature of rectangle tube with thin wall?...seems like it wouldn't do that with mandrel bending but i guess the mandrels just keep the bends from crimping...just wondered...what about trying a little thicker wall tube or is weight a huge factor?
Reply:Originally Posted by railin93i saw the notations at the beginning of the thread saying the bends are mandrel bent but why did the outside of the bend get concaved during the bend?...is that the inherent nature of rectangle tube with thin wall?...seems like it wouldn't do that with mandrel bending but i guess the mandrels just keep the bends from crimping...just wondered...what about trying a little thicker wall tube or is weight a huge factor?
Reply:*Update*Been working hard grinding, tacking, welding, and grinding some more to make sets of 3 "c's". Now that i have a bunch of sets I am tacking them together to create the full height.the pieces mocked up to give a sense of what the wall will look likeOne walls worth stacked together.This weekend i should be able to get at least half of one wall together and in the frame (4x1/4" flat)Last edited by MetalArchitect; 12-04-2009 at 02:40 PM.
Reply:Got a break from the wall for a bit, another project got pushed ahead...Trim pieces for  a reception desk, color will match that of the wall that I'm making.about 40' of kick panel, and 20' of vertical and horizontal trim.Had to make a simple 'jig'  to line up the flat bar in order to tack them together in a "T" and another to get a "L".  I wanted to make my own angles from two pieces since this is not structural in any way and it creates a sharp inside and outside corner (unlike rolled angle or formed plat which has a small radius)This is where the trim peices are going, the red area. The yellow is a 6"x1/2" angle for a kick panel.
Reply:damn.  nice job!  that wall will look slick, albeit a pita to fab.
Reply:Update Pics... One wall is Almost DONE!!! just have to finish the frame and body fill, sand and paint.The second wall is started but I still need to grind some welds before I can finish putting all the pieces togetherThe grinding is definitely the worst part...very time consuming and boring  but its fun seeing it come together!
Reply:looks great..very impressed
Reply:Looks very nice. When I saw the drawings for this originally, I thought the rings were much smaller for some reason..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:Okay, I'll say it ... I'm impressed.  That is some GREAT work on the wall, M-A.  All the time and effort you've put into it is really showing through.
Reply:awesome!
Reply:I would like to see a pic of this installed.  Nice fab work
Reply:Originally Posted by DSWLooks very nice. When I saw the drawings for this originally, I thought the rings were much smaller for some reason.
Reply:Wicked awesome, man! Is this just an ormamental screen?
Reply:Looks good.  Reminds me of something that I may have seen at the portland zoo some years ago. Are you T&M on this job?Common sense in an uncommon degree is what the world calls wisdom.
Reply:Thanks guys!... This is just an ornamental wall...just for visual effect!I should be finished with the fab work this weekend on both walls... then next week will be some finish grinding, body filling imperfections then primer and paint!The paint is a Metal Architect "custom" - a base coat of an antique bronze metallic paint than top coated with a mix of clear, black and a tiny bit of metallic flake (super fine), than a semi gloss clear.The results give a nice shimmer and a gold/bronze look in direct light that tapers to a dark brown at the far angles.Brainfarth - T&M?
Reply:Here is a sample of the paint- this was for the reception deck trim at the same hotel.Its hard to get the full effect from the pic (especially since there cell phone pics) but you can get the idea
Reply:Originally Posted by MetalArchitectBrainfarth - T&M?
Reply:I gave them a set price (which I thought was fair) and they jumped on it (seems they thought it was low)But i stand make a profit of more than 3 months pay at my full time gig, so I'm happy  Though I'll be glad when i can move on to the next project.
Reply:UPDATE PICS!was out in the garage till 2:30 am last night getting a coat of primer on 1 wall. Will finish up tonight and start getting some color on there tomorrow...I have a delivery date of this Saturday  So there will be couple more long nightsHoly crap! I thought a table for my basement was too big of a project....
Reply:They look great.When do you figure on being done, looks like you're almost ready to install.Brian LeonardAppalachian Ironworks L.L.C.434 Long Branch Rd, Marshall, NC 28753828 649 9966828 702 [email protected]
Reply:Applied the first coat of Bronze paint. Boy are these things a B*TCH to paint!!! there is so much surface area, with turns and little nooks between the pieces. It takes forever! LOL Should be done for Saturday!
Reply:Looks Great.  I'm thoroughly impressed.Thermal Arc Fabricator 281Miller 350PMiller Syncrowave 200Lincoln ProCut-55Jackson NexGen
Reply:I gotta admit I was dubious when you first showed us the drawings- but it looks like you figured it out, and are gonna make out just fine on this one.Congratulations.
Reply:Looks really good.       Sincerely,             William McCormick
Reply:Ok, it looks cool!Now for my question. I don't mean to be negative, but I do notice that many people percieve my questions as negative. So I wanted to make it clear that I am not naysaying, just curious.It appears that you had someone bend your C's for you. I assume you don't have a tubing bender.... so why not have them just bend the wave design in an entire stick of material? That would have saved all that welding and grinding right? Or with a 20ft stick of material, taking the waves out of it, I imagine would be long enough. I dunno. And I ask because I don't always see the big picture, so maybe in the future I will have something to go on by what I learn from your answer. Thanks!Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Whew!  Lotsa time involved in that one!  Looks great.Work HARDER, not smarter! ------------------------ Miller Bobcat 250Millermatic 251Lincoln Precision TIG 185Hypertherm PM 600Hobart 135 HandlerOxweld 400 FlameMaster
Reply:Wall is finally installed... I didn't install, the mill work guys that did the wood frame installed it... I dropped it off to there for them to make the frame for it...they must not have looked at the same plans I did because their frame was supposed to wrap around the edge of my frame so that you see the circles terminating into the wood. They didn't do that so now you see my frame (4x1/4" flat) and all the mounting bolts... we'll see what the architect says about it.Still looks nice though.Last edited by MetalArchitect; 02-21-2010 at 03:35 PM.
Reply:That is a great looking install!  Being a cabinet and mill work guy myself, I have seen the difference in interpretation of plans, especially if there is a designer involved.  It could be that there was a cost consideration from the plans to construction on the millwork part for doing the plow to wrap the frame.What are the ratchet straps for?  I would guess for handling it during the install.Reece
Reply:Great job!