I have been teaching Brandon [my grandson] to weld and he loves working in the shop and making special projects. Brandon is 15 and has Autism. He has been using my hood, gloves and apron and I thought it was time he had his own gear, so here he is working on a napkin holder with his new gear on. We'll go through the steps of making the napkin holder...
Step 1: Final Product - Welded Napkin Holder
Here is what the finished product looks like after being welded and painted....Now let's go through the various steps of how to get to this point...
Step 2: Raw Materials Needed
To start with, 5 pieces of 1/4" diameter steel rod are required for the project.
1 piece that is 24 inches long for the base, and 4 pieces that are 17 inches long for the sides.
Step 3: Creating the Base Pt. 1
Creating the Base with a Temporary Spacer Rod: To bend the spiral shape of the base, a 1/4 inch temperary spacer rod is used between the coils when bending. This picture and the following ones show how to make the temporary spacer from a piece of scrap rod using a rod bender with a 3/4 inch post.
Our rod bender is a simple home made plate with a 3/4 inch post and a 1/2 inch post.
Step 4: Creating the Base Pt. 2
Here is a shot that shows using the home-made bender and the 3/4" post to create a loop in the temporary spacer rod. This spacer rod will be used to create the actual base later.
Step 5: Creating the Base Pt. 3
Continuing with the creation of the temporary spacing rod. The actual base rod will be constructed by using cut pieces from this temporary spacer and bending around them...
Step 6: Creating the Base Pt. 4
After about two complete bends, the temporary spacer rod will look like the photo. We have shaded the area of the rod that will be used for the spacer. Remove the coiled rod from the bender and cut out [using a hack saw] and save the white shaded piece.
Step 7: Creating the Base Pt. 5
Making the Spiral Base:
Using the 24 inch rod, bend a tang approx. 1/2 inch long on each end of the rod.