Aluminum is my favorite

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Going through a bunch of old pictures, found some more stuff ive built over my short career.I like fabricating aluminum the best, Its what i learned to weld first, and made learning steel, stainless, copper, titanium, zinc, etc so easy when i learned them.  I know its been discussed in other threads, but i think it is best to weld aluminum first. I learned at one of the best community college welding programs in the county, and they have been doing it that way since the 60's amd turned out some incredible welders, but i digress.Pic 1: all aluminum saw stand for a festool mitre saw ($1300 for this bad boy, definitely worth it if your a trim guy, the quality and accuracy is incredibleThis was taken just after i finished it on buddys ranch, as the sun was going down over the oceanIts mostly 1.5" X 2" .120" box tube.  The legs are compound mitred and the whole things dissassembles and will pack into the back of a pickup.Pic 2: The only thing i didnt build were these aluminum tops with wood underneath.  Its got  8'+ to the left of the blade and 6'+ to the right of the blade,  Everything is adjustable and can be leveled dead flat.Pic 3: I started this job awhile ago as a work trade for a contractor who did some framing for me.  We built the main stand and tables, but we wanted the tables to be supported so i added the kickers you see in the first pic.  he also wanted a rolling base.  So i designed the base, adjustable casters slide in bushings and get tensioned with the T handles.  Its strong as can be and rolls like a caddy.The entire saw stand gets lots of compliments wherever he takes it.  The best part is, he can assemble the entire thing, by himself.  Wish i had more pics, but my memory card fried and i had these on my hard drive.Some of the welds are sooty.  I didnt acetone, or wire brush any of the tubing.  It still welds fine, im not that picky and neither is he.  Time is money, i dont have time to weld prep everything i do, its about getting the job to an acceptable level and moving on.Pic 4:Headache rack i built for my dodge.  Had some leftover tube from the saw stand and some .25" X 2" flat bar.  I bought the LED's ($220!!!) Pic taken when i finished up in the garage at home.Pic 5: How it looked after a year of being on the truck.  I used this thing alot.  It saved my cab a couple times moving hay, firewood etc...I once hauled 14-20' sticks (about a 1000 pounds) hanging off the back of this thing, and no problems at all.I sold it to a buddy when i bought my full lumber racks. Barely made back what i had in materials, and i added 4" to the bottom so it would fit on his ford, but hes happy, and it paid for my new rack.Cheers Attached Images
Reply:503 views and no comments Oh well, here's some more aluminum projectsHere is a hidden door that was down in a massive stairwell leading down to a basement at an estate we did a bunch of work at.Cant show a picture installed because of NDA's but here is how i built it.Contractor wanted the door to be as hidden as possible.  Originally he tells me he wants a removeable door, that they will be able to stucco over and will be mostly hidden.  It is an access door to a mechanical/pump room.I asked if he wanted it be hinged? He tells me no, not neccesary.  (the door is so heavy with the stucco that it sags when its opened, which luckily is seldom)  The door probably weighs over 200 pounds with all the stucco on it.  Should have gone with bigger hinges and larger flat bar, but it works and the weight keeps it from coming open (we were thinking we would have to add some sort of latch system)Anyways, its all aluminum to keep the weight down except for the steel hinge system.Its totally adjustable up, down, left, right and the top can be adjusted in and out.  it was designed 1" smaller than the RO all the way around so they could shim it look a standard door way,  Looks unbelieveable installed! contractor did a great job on the stucco and finish work,  The gaps are so tight that someone has to show you the door or else you would probably never even see it, cool detail on an amazing home. Attached Images
Reply:File cabinet locks for a car dealership.The locks on these cabinets kept breaking, and they wanted something simple, and reasonably pricedI came up with these.The bottom is anchored with one way screws into the toe kick of the cabinet,  The top plate has the screws covered when the bar is in place, and they are secured with a padlock, which was keyed to their master key system.  Kind of bulky, but they loved them.All visible welds detailed and smoothed, with a DA finish and my special trade secret sealant. Attached Images
Reply:Missed this 1st time thru. I like the saw table. The only down side looks to be the fact it's quite a bit to set up for small jobs. I would have loved to have had one like it a few years back when I spent 3 months trimming out a lot of detailed woodwork at one job however. I set up a semi permanent wood bench in the garage for one saw to do repetitive production work, and then had a 2nd portable one to take from room to room.I also like the lock bar. Is the top welded up and then finished or did you machine the whole piece and attach it to the bar?.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:I guess nobody likes Aluminum. Sorry no ones commented.    Very impressive work, it looks like you even have a turret press. The only aluminum I handle is a can.
Reply:Beautiful craftmanship bro I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by DSWMissed this 1st time thru. I like the saw table. The only down side looks to be the fact it's quite a bit to set up for small jobs. I would have loved to have had one like it a few years back when I spent 3 months trimming out a lot of detailed woodwork at one job however. I set up a semi permanent wood bench in the garage for one saw to do repetitive production work, and then had a 2nd portable one to take from room to room.I also like the lock bar. Is the top welded up and then finished or did you machine the whole piece and attach it to the bar?
Reply:That door is sweet how does it latch or open if there's no visible handle does it have some kind of pushing mechanism so it pops back out or a remote operater opener or something cool like in the movies where there's a book on the shelf that you pulled down and then the door springs open?  All of that's real nice work.Millermatic 135Craftsman 7 Hp 80 Gallon           2 stage compressor
Reply:I welded a bunch of similar square tube into a rack for storing and dispensing rolls of wire.  I did what I though was a really nice job.   pretty much my first paying TIG welding job.  I used 5356 I think.  I delivered it all happy and proud.   they called a day or two later and said it was cracking.   the cracks were not visible when I delivered it, they just appeared over night with not use at all.I got to reweld it all. I read about online and used 4043.     Very emberasing.   But it has not had any trouble since.  And they hired me for a second rack to be made later on.anyway, nice stuff.    what filler did you use and do you have any tips for a guy with low experience to prevent the cracks?
Reply:Originally Posted by dsergisonI welded a bunch of similar square tube into a rack for storing and dispensing rolls of wire.  I did what I though was a really nice job.   pretty much my first paying TIG welding job.  I used 5356 I think.  I delivered it all happy and proud.   they called a day or two later and said it was cracking.   the cracks were not visible when I delivered it, they just appeared over night with not use at all.I got to reweld it all. I read about online and used 4043.     Very emberasing.   But it has not had any trouble since.  And they hired me for a second rack to be made later on.anyway, nice stuff.    what filler did you use and do you have any tips for a guy with low experience to prevent the cracks?