My friend is getting married, I'm best man. I always told him I'm going to make him a ball and chain when he gets married. Having my previous instructable
Medieval shackles https://m.instructables.com/id/MEDIEVAL-SHACKLES/
I decided to use that concept to make my ball and chain sculpture for his wedding gift.
Step 1: What You Will Need
For this you will need a
-grinder( I have three plugged in, one with a flapper disk, one a wire wheel, and the last a grinding disk)
- c clamp
-wire wheel(for drill)
-A shackle made for leg,
To see how to make shackle visit
- I used rings that were wrapped in plastic, used as a seat on a dining patio chair, 4 rings in total
Step 2: Finding Centre
Using a piece of cardboard, and a 45 degree angle mark a 45 from a corner of the cardboard.
Placing your ring on the perpendicular edges, the drawn line will give you your centre on the rings.
Mark on your ring Both sides for centre
Step 3: Cut Rings in Half
Using the marks you put on the rings in the previous step as a guide, cut 3 of the rings in half. Leaving one full ring.
Step 4: Cut Ends Into Angles
On 4 of the half rings. Measure an inch down from the cut. Draw a line . Draw a perpendicular line in the middle of the ring , and draw two lines making a triangle(see picture)
Cut alone this line making the rings ends into points
Leave the other two half rings with a flat end
Step 5: First Welds
Making sure the half ring is as close to 90 degrees as you can weld the first half ring in place. Flip it upside down placing it in a vice to weld the second half ring.
Step 6: 3rd, 4th, 5th and 6th Half Ring
Use a c clamp to pinch one end of the half ring in place, it makes welding the free end easier. Using this method weld the 3rd, 4th, 5th and 6th half ring in place
Step 7: Cutting U Bolt
I had these ubolts with nuts welded in. I figured I could use this to connect the chain. Using your grinding disc cut out the nut. Grind out the welds and clean up ubolt.
Step 8: Putting Chain in Ubolt
Link the chain through the ubolt, place it in vice so it's easier to work on.
Weld nut back in place.
Step 9: Attaching Chain to Ball
Weld a washer in the centre where all the rings meet. Weld inside of the washer
. Then weld the ubolt over top the centre of the washer. Your shackle is now connected
Step 10: Hiding the Cracks
Using more big washers, weld them on both the insides where all the rings meet and on the other outside .
Taking a larger ball bearing , weld them in the centres of the washers.
Doing this hides most of the seams and welds holding the ball together
Step 11: Cleaning Up
Using the drill wire wheel, grinder wire wheel, and flapper disc, clean up the metal, clean the edges, and the welding marks and spatter.
Step 12: Your Done
Thanks visiting my bachelor party idea/ wedding gift. Feel free to post your own. I made this so it can be put in a garden or hung up and just leave it laying around
Step 13: Second Ball and Chain I Made.
A friend had a big steel ball in which I acquired it. Wrapping it with steel straps and welding a chain and shackle on I was left with a different style ball and chain. Less bulky , more heavy.