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Step 5Cutting the metal crossbar.

Cutting the metal crossbar.
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Now we need to cut the metal crossbar. This is a very important part, as it spreads out the pressure and prevents that pipes from bending outward. (I added this part after I finished to fix this exact issue. Oops - Live and learn.)

I may have lied earlier when I said you already did the hardest part. (Back in step 3) This CAN be hard if you want it to be hard.

You need to measure the distance between the pipes fairly accurately. in order to find the location for the crossbar holes. If you get it slightly off, it's OK. You need some slop in the holes anyway to help slide the cross bar up and down.

This is the hard part. Once you have the locations for the holes, drill them. It will be about 1" in diameter. If you have a stepped drill bit, this will go easier. Don't try to just drill a 1" hole into steel. It's just not worth it. In fact, that's about the best way. Hole saws will hate you... don't use a wood bit... I had a 3/4" stepped bit, and then I cut the rest with a rotary tool. My drill press wouldn't do it, and my mill was in many pieces.

Once you get the hole cut, fit the crossbar on the pipes. Make sure it slides up and down freely. Grind it down and clean it up to make it slight up and down freely, but don't make it too loose. If it's too loose, it won't support the pipes when it is under pressure.

STEP 5 - DONE! WOO HOO!
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Author:bgraham111
I work as an engineer. I am slowly building my home machine shop (and skills). I like to tinker and make, but I'm mostly on the mechanical side of things. I work with FIRST robotics teams. Always look...
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