Step 1: Materials and Tools
Copper and solder, aswell as a blowtorch.
Hose barbs- if you use copper you can use brass or plastic barbs
- if you use aluminum you can use aluminum or plastic hose barbs.
-plastic ones can be cheaply found in the plumbing and garden section. Instead of buying the white nylon ones you can use the cheap plastic abs ones. Mine are toro. I only used a nylon one because I had it on hand.
You can't use aluminum in the same system as copper or any less reactive metal because the aluminum will corrod due to the electrical potenetial between the elements.
Glow ind the dark powder coat paint
I used this in addition to my blue:
Metal Cutting Bandsaw
Step 2: Mark Out Your Pattern
If you printed it out glue it on to the metal with rubber cement.
Use your center punch to punch a spot in the center of each hole so that you know where to drill.
You can use a nail as a centerpunch.
Step 3: Drill Out the Holes
I used a lathe for some parts and a drill for others.
If you have a drill press you can use that.
Step 4: Prepare for Bonding the Base to the Top
If you use a belt sander I recommend you use a lubricant to sand. The aluminum can clog the sandpaper without a lubricant.
I used WD40.
Cut out a piece of metal for the top. Sand it before bonding.
Step 5: Attaching the Lid to the Base
If you use JB Weld, mix it on a seperate platter and put a small bit around the circumference of the block, press it on and clamp it.
If soldering clean and sand the surface. Flux it. And heat up and solder.
If you are using copper ou can use brass hosebarbs and solder them in.
Afterwards drill holes in the lid for the hose barbs to go into.
Lap the base with increasingly fine sandpaper. I didn't do this step. I stayed with course sandpaper and just lubricated it which made it cut much smoother.
Step 7: Paint
For mine its was 20 minutes at 400 degrees farhenheit.
Step 8: Attach Hose Barbs
Jb weld the hosebarbs into the body.
If you have extra jbweld on the barrbs, use wet q-tips to wipe the extra jbweld off.