TIG filler organization rack

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So I've accumulated several boxes of TIG filler over the years and I'm tired of it being dirty and unorganized. Recently my department came upon a windfall of capital equipment dollars, so I purchased a JMR mfg dimple die and punch set. It's a pretty slick little setup and came with 5 different sizes of dies. The punches require a 3/4" pilot hole, so I use a step drill for now because it's fast and effective. I also bought a slugger sheet metal holesaw kit, but I haven't found a failsafe debuting process for that yet. Here is the JMR set I picked up from Trick ToolsSo I decided to buy a set of rod guards for TIG filler and build a sweet little tack to organize them on the wall. I'm a huge fan of displaying good workmanship in the shop and give examples of what each tool is capable of producing to try enticing my student population to build other cool projects. I started with a piece of .100" aluminum (5052) that I had left from cutting coupons once my box got full. I layed out the rod guards, pressed a test hole on the same Al sheet and got down to business. I came up with a 2 tier rack that the rod guards would more or less hang in. I sheared up the sheet and formed it on my straight ️brake. Layed out the hole locations and pilot drilled them allThe 2" punch takes a 3/4" pilot but the 1" only takes a 1/2 for additional clearance. This is why there are two different sized holes. This is how it will eventually sit once it's done:Sent from my dumb smartphoneTeach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:If you follow me on Instagram, you'll see progress in real time, but here's a video of the JMR press in action:And the dimple dies pressing the 2" hole Yes, I know I have a wicked air leak, but its only on this coupler, so I'm not super concerned. Here's what it looked like after dimplingAnd with a few rod guardsSent from my dumb smartphoneLast edited by teachagmech; 03-19-2015 at 11:08 PM.Teach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:Wow that is sooo freakin cool!!!!!Cant wait to get my shop put up and fill it with all sorts of new tools!!! I would love to have a dimple die set.Of course, first I need land to put the shop on....
Reply:Since I'm a raging loose tool wh0re, and my school district enjoys buying the latest and greatest technology I probably have more tools than most ordinary shops. That being said, I remembered I had some extra red anodized dog tags left from a project we did as awards for some kids and thought they would make a snazzy set of ID tags for each variety of filler. So I grabbed a old piece of clear acrylic I had and set to work making a fixture for my VersaLaser to hold these dog tags. This would give me an easy go-to for the next time I make a run of tags. I drew up the text and set the tags in and engraved the lettering on the laser. Then I drilled a hole on the other side of the tags so I can fix them in position with pop rivets. Sent from my dumb smartphoneTeach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:That is cool, I don't have nearly enough filler rod from my last job to fill 2 of those slots.
Reply:Originally Posted by bostonbrandThat is cool, I don't have nearly enough filler rod from my last job to fill 2 of those slots.
Reply:teachagmech,That is pretty cool.  When you dimpled all those holes, how much did the plate warp? If it did warp, how did you straighten it?
Reply:It actually didn't warp too bad. The dimples add rigidity by themselves. I dimpled after forming (obviously) so for this, a little warpage was really no big deal. Sent from my dumb smartphoneTeach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:Dam thats nice!!! so how much when you start selling them?Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Originally Posted by roadkillbobbDam thats nice!!! so how much when you start selling them?
Reply:class project to raise money for some good cause................Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Originally Posted by roadkillbobbclass project to raise money for some good cause................
Reply:good luck either way.. it would teach responsibility and some business sense along with the skill needed to produce the product...Of all the things I lost I miss my mind the most...I know just enough about everything to be dangerous......You cant cure stupid..only kill it...
Reply:Great man! I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:When I made my first post I didnt think it could get any better. But it did! Wow that looks so cool.
Reply:And I'm almost done!I got the sides cut, broke, punched, dimpled, then welded on Here's a closeup. Not too bad for a guy who doesn't do this every day. And then I hung it up in its new homeI still need to get my pop rivets to fix the dog tags in placeSent from my dumb smartphoneTeach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:In case anybody wants to build one, here are the rough plans. It does hold 12 rod guards, and I only have 10 right now. I need to get 2 more, but I'm sure you could find a use for the other spots. No dimples are necessary, they just look cool. The side plates were just traced from the ends of the formed piece. Make it your own and have fun!Sent from my dumb smartphoneTeach Ag Mech - Mike At Home:Lincoln Electric AC225Miller Challenger 172Gas AxeWork:eclectic bunch of 90's vintage blue boxes
Reply:Originally Posted by weldermikeGreat man!
Reply:Very nice work and extra points for style Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Craftsmanship...  The details do count!  Not only totally functional but nice to just look at.
Reply:Nice organizer.  I guess I missed it, but what are the smaller holes for?Burt _____________________Miller Syncrowave 250Millermatic 211Miller 375 Plasma Cutter Hobart Handler 12010FtDrillBit.com
Reply:Originally Posted by wb4rtNice organizer.  I guess I missed it, but what are the smaller holes for?
Reply:Really awesome design. Saved this page for when I get my ac tig machine. But now I need to get a dimple die set too TOO MANY TOOLS & NO MORE SPACE
Reply:Originally Posted by Chris T.Really awesome design. Saved this page for when I get my ac tig machine. But now I need to get a dimple die set too
Reply:Originally Posted by teachagmechSimply for style points because they look cool Sent from my dumb smartphoneWow, that is great. Thanks for sharing and giving specs.Awesome job
Reply:Originally Posted by wb4rtI'll agree they do add style to the rack, but seems like a lot of extra work. And with my ability, they wouldn't line up and then it is all "out of style"!My thought was you were going to use some small tubes in those holes for short pieces of filler rod. You might use half of the 1 # plastic tubes, if they fit. I have a place on my filler cart for short pieces that I use all the time.I'll have to look for a dimple die set that I can use on my HF shop press. Any one have a suggestion for that?