*DISCLAIMER:This is in no means a tutorial on how to weld, yes basic instructions will be required, but a MUCH more in depth knowledge of welding safety is required, I will not have on my conscious someone's mistake nor will I take blame for it. If looking for a welding tutorial I suggest this one https://www.instructables.com/id/How-to-Weld---MIG-Welding.*
This past Christmas I became very intrigued in the art that is welding. After I saved up the cash and learned the basics a bought a Hobart 140 mig welder and required tools to do basic welding. To my dismay I quickly realized that simple passes on some hot rolled stock would not be enough to feed my lust. I came across a fantastic website (weldingtipsandtricks.com he has a YouTube channel by the same name that provides videos as well) that showed him creating a steel die from hot rolled steel flats.
Step 1: Acquire Appropriate Supplies/Tools
- Welder-I will be using a Hobart Handler 140 MIG welder and it's corresponding feed speeds and amp outputs from here on out.
-Something to cut and deburr the steel whether it be a hack saw and a file (if you've got the time) or a angle grinder. I used a Ryobi angle grinder and a Dremel Saw-Max
-welding brush for steel
-vice grips (optional but helpful)
-welding magnets (I don't know their proper name)
-square (a ruler and marker too)
-1/8" drill bit capable of drilling steel
-drill (optional drill press)
-3/16" solid flat hot rolled steel (4063) 2"x36" is the length I found
-appropriate safety including but not limited to a welders helmet, at least jeans, a ventilated work space (or outside), and a thick leather jacket, shoes, and gloves
Step 2: Cut the Squares
This step involves simply measuring the steel flat from side to side because they rarely are a perfect 2 inches, mine came out to be 1 15/16" -1 31/32" so beware. Mark your piece and cut, if using an angle grinder the steel can get red hot so have a bucket of water near by. Dunk them using pliers don't just drop them unless you have a sheet of metal on the bottom to prevent melting holes in the bucket (I've learned the hard way). Once all seven are cut deburr and straighten with a file or a flap disk on an angle grinder.
Step 3: Create a Template
You are going to need to measure off 7, 2 inch squares one by one then cut (measure then cut each one individually to keep them accurate). The first will be the template which needs 9 holes, this will be easiest if you score the middle line (1" from each side) then the middle from the side to that line on each side (it should be a 1/2" from each side. Where the lines intersect (there should be 9) drill a 1/8" hole via drill press or drill and vice. This is necessary to be accurate otherwise the holes will be off for every side.
Step 4: Drill Holes for Sides
*NOTE: drilling holes is necessary for welding a inclosed hollow object*
I drilled the holes in a vise because I couldn't hold them on a drill press, but if you can more power to ya'. Even with plenty of batteries this took me around a half an hour so be prepared for cramps. (I suggest drilling from 6 to 1 just for your sanities' sake)
Step 5: Weld the Sides Together
Finally! We're here. I apologize since when I originally did this I didn't think of making an ible out of it so the welding pictures will be lacking slightly. To start I selected the measurements my welder required which for a 3/16" steel piece without gas using .30 flux wire (yes I'm using flux core, buying the welder really busted the bank I couldn't in good consciousness spend 150 for a tank and gas too) are 4 on the voltage settings and 50 for wire speed. 50 personally, was a bit splattery so I turned it down to 45. If you wish to have an accurate die with correctly positioned faces I have provide a photo of a die's net. Once ready weld the first 90* angle using small magnets and a vice. After that some creative thinking is required to keep the sides in their correct spot while you tack them up, this will be up to you and what you have available. Once the four "walls" are built lay on the top and go to town, and then come back to finish the bottom.
Step 6: Enjoy!
All jokes aside, I hope you have learned through this Instructable if you have any questions ask in the comments. Thanks for reading, if you enjoyed this please vote, favorite ,and follow for my next ible a Headlight lamp.