Step 1: Stuff Needed
- Metal tubing (square and round)
- Welder (I used a MIG but TIG and stick should work)
- Chop saw
- Acetone or another solvent
Step 2: Cut the Pieces
Once the stop was set to the wanted length (1.25 in.) I kept repeating the same thing over and over, turn on, add oil, ease the saw down, add oil, lift the saw, undo the clamp, push the metal farther in, and repeat. This is where patience comes in.
Step 3: Solvent Bath
After I cut the pieces, I found that they were greasy from the saw so I soaked them in acetone. This step isn't required but it is recommended so the metal doesn't catch on fire when it's welded.
Step 4: Arrange
I then turned the pieces on their end and arranged them, though I arranged them randomly you could:
- Draw a picture
- Write a name
- Or leave the middle open and use it as a picture frame.
Step 5: Weld
Once the pieces were arranged, I clamped the work clamp to a piece and tested the settings. With the settings changed I started welding the pieces together. Though not my best welds, it's not going to be put under stress so it doesn't really matter.
Step 6: Admire the Finished Product
Time to set the "rug" down and watch people get blasted with awesomeness.