Cast Aluminum Chair Repair

[Don52]

11. Chair all done


Now some pictures of Meadow Brook Hall:

12. Meadow Brook Hall 1


13. Meadow Brook Hall 2


14. Meadow Brook Hall 3


15. Meadow Brook Hall 4


-Don
...

[Don52]

6. Welded from 1st side


7. Back brace weld 1


8. Back brace weld 2


9. Back rest weld 1


10 Back rest weld 2

...

[Don52]

My friend Chris works as a docent at Meadow Brook Hall, which is an 88,000 square foot 110 room mansion in Rochester Hills, Michigan, which was originally built from 1926 till 1929, by Matilda Dodge Wilson. For more information see:

https://en.wikipedia.org/wiki/Meadow_Brook_Hall
...

[Don52]

11. Weld 2


12. Weld 3


And here are two pictures of the aerobars with the diagonal brace in place.

13. Close up of diagonal brace


14. All done


One thing that I like about this forum is comments tha t if taken...

[Don52]

And here are the tubes all done.

6. Tubes all done


To make the feet I cut out the drawing of the feet and glued the drawing to a piece of aluminum.

7. Cutting out feet


The cost of the original aero bar assembly was $21, so I purchased...

[Don52]

Ryan,

Sorry, I’ll get right on it.

-Don...

[Don52]

Adding Third Arm to Bird Feeder

My wife decided that she needed one more feeder, so I converted a two-arm bird feeder pole to a three-arm pole. The larger birds and the Oriels are hesitant to go to the feeder closer to the house. They are more comfortable using a feeder further from the...

Dave,

Please approve my post: "Riser for Bicycle Aero Bars 2"

-Don

[Don52]

Back in April I designed and built a riser for my aerobars to create a more comfortable position for my forearms while using the aero bars on my mountain bicycle. Here is a link to the post.

https://weldingweb.com/vbb/threads/7...ycle-Aero-Bars

The following...

[Don52]

I do have a nice Innerstate boring and facing head, that looks like this.
The facing head would have certainly worked. I felt that feeding in with a 1” diameter cutter would be quicker. Once I figured out how to eliminate the chatter, I believe that it was quicker.

-Don...

[Don52]

My first attempt to face the boss was to use a 1” endmill and use the quill to plunge the cutter into the boss. Due to the interrupted cut the finish was badly chattered. For my next attempt I locked the quill in the fully retracted position and used the knee of the Bridgeport to control the feed...

[Don52]

Thirty years ago, my friend Mark rebuilt the calipers on this 1965 Corvette by adding stainless steel sleeves to prevent corrosion of the bore of the cylinders. At the time they used the original piston. They replaced the seals with lip seals that were the original seal design that had a very high failure...

[Don52]

11. Cross plate painted


12. Point painted


I still have to install the pole and make the 2^nd swing arm. Attached is a link to a one minute 22 second video showing the machining steps that I used to make all of the parts. It turns out that there are a lot of st...

[Don52]

6. Cover pass


I chose to use Dual Shield Flux Core wire (FCAW-G) to attach the cross plate to the tube. The plate is 3/8” thick and I was concerned with penetration if I used short circuit MIG. Here are the parameters that I used:

Process: Dual Shield flux core (FCA...

[Don52]

Recently I remodeled the family room. As a part of the renovation, we replaced the windows. The swing arm that supported two of the bird feeders was attached to the frame of the old windows. We didn’t want to attach the swing arm to the new windows, so I designed a sturdy 1-1/4” black pipe pole...