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The Fallout shelter 14'X40'X80'

56479 Views 933 Replies 14 Participants Last post by  Rusty Scupper, 
firestopper
Back in 2013 I decided to build a detached shop next to my home. For 15 years I had been working out of an attached 26'X50" but it seemed I had acquired too many machines and quickly found myself unable to park any rigs inside. Living in the SW desert of Arizona, I was at full time war with packrats and the harsh UV rays of the sun. I wanted something large enough to address it all. My old shop had a large Band saw, cold saw, lathe, mill, pipe bender, CNC 5'x10' plasma table, several tool boxes, a compliment of miller welders, 51Ton iron worker and a 4'x12' jig table just to name a few. Needless to say all automotive work was preformed outside.

A last look of the old shop.
Motor vehicle Automotive design Engineering Industry Factory


After pulling a large Palo Verde tree and relocating a 40' sea container I was ready to layout the new pad.
Tire Wheel Vehicle Sky Car


Forming and importing dirt as well as laying out all the anchor bolts for the 10 columns.
Cloud Sky Wood Road surface Asphalt

The night before the 3am pour.
Automotive lighting Light Street light Road surface Asphalt

The foundation was poured in mid July with temps averaging 105º.
A 44 meter pump truck kept the flow coming. I had hired eight finishers for the day myself included.
The fella at the drivers side outrigger at the pump is 6'3" so it gives you an idea of the size of the pump rig.
Cloud Sky Road surface Asphalt Vehicle

The power finisher doing its magic.
Cloud Sky Property Tire Road surface

Finished up around noon for a 9 hour day. I kept the water on for 7 days to counter the hot days.
Cloud Sky Tree Asphalt Road surface

Another shot from the NW corner. You can see the 1.5" notch around the perimeter. This will secure a 3" base flange with the skins over it to keep water out. The hose entering the slab is a "man door" location. The west end will have
two 10' x 12' garage doors. the NE side will have a 10'X 12' rollup door (2 post lift), and the SE end will have a 10'X12'
garage door aligned up to the one of the West doors for a drive through option.
Water Plant Watercourse Composite material Tree

About a week later the delivery from El Paso arrived with the kit I purchased through Mueller inc. They were great to deal with every step of the way. The provided all the engineering to satisfy my county. The only thing I had to source was a foundation with an engineering stamp for all the steel in the piers and footers.
Cloud Sky Vehicle Wheel Tree

Between the drivers crab style fork lift and my Hyster, we made short work of staging the "red iron".
Cloud Sky Tree Road surface Mountain

More to follow.
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mp06011999
firestopper said:
I never knew about the oven cleaner for rusting but I have used it to degrease decades of gear oil on the knuckles on the 40 when I rebuilt the front axel.
I’m glad you enjoy the posts. Some are better than others but I try to keep it informative.
Merry Christmas brother!
Click to expand...
I'd read years ago to use lye to rust / corrode bare metal. That's easy enough to get in oven cleaner. Spray and leave it on. Reapply. It'll start to pit and age in maybe a week or so if you don't rinse it off. I also spray it with salt water after the metal shows corrosion from the lye. On the wood finishes it'll strip the protective coating right off and keep destroying... uh hm, I mean aging it pretty quickly. Once the varnish is gone I spray it with water, soaking it and let it bake in the sun where the pores will open up. Turns it old real fast doing that.

Funny, out west here we have to come up with ways to do what wet / salt / snow country does naturally - lol.

Always enjoy your posts. Keep it up and Merry Christmas to you and yours as well.

Edit: Oh and I almost forgot, if it's thick enough metal, placing it in a relatively cold fire will age metal immediately. Like a fire made with boxes and paper and maybe a little wood. But too hot and it'll warp it.
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firestopper
The Standard

With the scuppers on hold due to a constant drip from condensation, I turned to another project. I've always wanted a real flagpole. What I mean is not a cheap aluminum pole with limitations on the size of flag you can fly without fear of failure. I have two 19' sections of sch.40 pipe, one being 4" (main base) and 3-1/2" top section. These sections have been stored outside for some 15 years. That said they were buried and full of cacti from those pesky pack rats.
The hole;
With an 18" auger the mini was able to reach 72". I did have to jackhammer a few large rocks during the process.
Sky Vehicle Road surface Tree Asphalt


With a depth of 72", I calculated 1400 pounds of concrete would be required (.38 yards).
Slope Line Bedrock Geological phenomenon Soil

The set up for clearing the ID of both pipe sections and wire wheeling the exterior surfaces.
Notice the Oxy/Acetylene cart. I rarely use this since the plasma is my go to for cutting but nothing can replace the power of energy produced with the proper mix. Key word being proper mix....
I draped rags over both ends of the pipe and introduced about 6 seconds of acetylene followed by 4 seconds of pure oxygen. I then lit the torch and introduced the flame to the Chamber end. 🤣 You guessed it! The resulting cannon shot all that rat poop, cacti and other debris out the barrel. The rat was recovered 15' away and was completely inverted (inside out). Prolly should have used 2 seconds of O2. The boom was quite impressive I must say.
Tire Wheel Sky Vehicle Motor vehicle

Honing the ID of the 4" pipe to slide in the 3-1/2" pipe.
Notice the 6" steel ball. This will adorn the top of the flagpole.
Road surface Asphalt Wood Building Sky

Building the sleeve.
The sleeve is a remnant piece I sourced but it has an ID of 5-3/4" while the main pole section has a OD of 4-1/2".
I came up the a solution while laying in bed. A self centering weldment for the bottom while the top will have four jack bolts 90º apart. The inner circle in the layout represents the ID of the 4" pipe while the outer circle is the OD of the sleeve.
Cone Gas Wood Hat Electric blue

A test fit!
Asphalt Road surface Flooring Gas Tints and shades

Welded in the base of the sleeve.
Plant Road surface Asphalt Street light Line

Looking down at the base you can see how the self centering feature will work.
Automotive tire Wood Gas Automotive lighting Rim

A test fit of the sleeve before it get too heavy. A reference mark on the main section proves it seats centered. The top end jack bolts center the pipe and can be used to fine tune plumb. The end will be welded with a rootless followed by a cover pass. I'll probably burn 1/8' 7018 or 7024 rod. I will need to roll two half pieces of 5/16" round bar to fill that 3/8" gap. Once the two are welded, the four jack bolts will be removed and plug welded for aesthetics.
Road surface Wood Composite material Gas Tints and shades

Rolling 12" #4 rebar rings.
Silver Font Circle Nickel Metal

More to come...
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firestopper
With the six #4 rings welded, the rings were then welded to four #5 rebar legs. I also welded a 40" piece to the center of the sleeve. This piece will allow (hopefully) for the entire sleeve assembly to be adjusted without having to dig out the bottom of the hole for leveling. At this point the bottom is unreachable. The plan is to stab the center rebar as close to eyeballed center as possible.
Wood Motor vehicle Flooring Floor Automotive design

Ready for the plumbing form I have designed in my head. I plan on a UFERS to ground to the rebar and clamped to a 8'
ground rod.
Automotive tire Plant Road surface Gas Asphalt

That's as far as I got yesterday.

Another share for you fellas. Ive been wanting a remote control foot peddle for the Tig but they just cost too much these days. Anyway I found this brand new never used unit on eBay. I mad an offer and paid 1/2 of what they go for and batteries were included.;)
Brown Font Table Eyewear Material property

The bluetooth unit has a great range and will eliminate another wire on the floor.
Electrical wiring Cable Audio equipment Electricity Gas

The machine end is a 14 pin that pairs up flawlessly.
Motor vehicle Hood Automotive exterior Fixture Electrical wiring

The old wired foot amp control.
Tire Wheel Automotive tire Tread Motor vehicle

Despite 2022 being a sh**show, I reflect on how blessed I have been to continue to chase my joy in fabrication.
I want to wish all of you the same blessings I have been given and wish you all a very Marry Christmas and a healthy, productive New Year!
Your brother in AZ.
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OkDually
Nice score finding the pedal for the TIG!
It is a great addition to the equipment.

Merry Christmas to you and your family, Paco!
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firestopper
OkDually said:
Nice score finding the pedal for the TIG!
It is a great addition to the equipment.

Merry Christmas to you and your family, Paco!
Click to expand...
Thank you sir!
I’ve been looking periodically over the past year for that Miller remote. Once in a while you can still find great deals on eBay but it’s not like the early 2000.
Merry Christmas to you and yours as well brother.
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R
Another great project. Look forward to a pic of the end project with Old Glory flying high.
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Pure Diesel
That's one hell of a stripper pole your making.
What size flag are you going to be flying?
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firestopper
Pure Diesel said:
That's one hell of a stripper pole your making.
What size flag are you going to be flying?
Click to expand...
Howdy!
Planning on a 6x10 and on Memorial, Veterans, and July 4th a
8x12.

Rusty Scupper said:
Another great project. Look forward to a pic of the end project with Old Glory flying high.
Click to expand...
Thanks, I’ve been wanting to fly colors for some time.
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firestopper
Update on the flagpole pier.

I got an early start on Monday and picked up 24- 60 lbs bags of redimix from HD. I requested them on a pallet so
for a $20 deposit I was able to use the forklift to unload the trailer. The forklift was staged next to the 3 bag mixer so every bag was easily slid onto the drum lip and cut open without using my back much. The opposite side of the mixer was a wheel barrel with the hole 4' away. Very efficient with minimal lifting. The large rack and pinion and helm makes it effortless to rotate a rotating load of 300 pounds. I mixed five bags per batch a little on the soupy side. One batch made 3.5 wheelbarrow loads so not too bad. the process took 40 minutes.

An adjustable jig form was made to maintain plumb while pouring. The same four adjusting jack bolts will be used in reverse to fine tune to sleeve once the form was secured.
Pipeline transport Plumbing Gas Sanitary sewer Circle

The I shape design is staked down and its low profile makes it easy to work around while pouring and vibrating.
Road surface Asphalt Tar Cone Road

The jack bolt design worked well and was made from scrap.
Sky Automotive tire Wood Asphalt Road surface

Ready for mud.
Asphalt Automotive tire Road surface Cylinder Composite material

The receiving side of the hole was ramped prior to dropping in sleeve.
Automotive tire Road surface Asphalt Cone Gas

A Ufer was added. The #4 solid copper wire will terminate to a 8' ground rod.
Automotive tire Asphalt Gas Circle Auto part

With 24 bags in the last four will be poured after the flagpole is inserted, welded, and the four jack bolts removed and plug welded. That means I need to remember to insert the 16" Sontube and rebar coil before the pole is set. The final ring visible will tie in with the rebar coil after it's poured. I think an elevated round pedestal will look nice when done and will keep the bare pipe from contacting wet dirt.

With 1,680 pounds of redimix, Im sure I can fly an 8X12 flag in decent winds.
This project has me a little excited. 🇺🇸
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firestopper
Punched more holes for a front fence and privacy fence along the front of the shop.
In an effort to maintain 10" O.C. I tacked short sections of 1.5" angle iron with the V facing up. This allowed me to place a precut length of 14 gauge 1.25 x1.25 square tube to serve as a spacer. A string line kept thing lined up and the transit help set elevation. The mixer and forklift were staged close together and close to the holes. Working alone requires little things like the spacers and keeping things efficient as possible.

The short pieces of angle were tacked in two places and only on the underside. This makes it easy to break off once the mud is set. Basically step on each piece and it breaks off leaving two small tacks to grind smooth.
Automotive tire Road surface Wood Tire Asphalt

Maintaining an 1/8" slip fit between each posts prevents the spacer from wedging. Using the spacer with a corner at 12)'clock ensured minimal sag on the spacer.
Slope Road surface Asphalt Wood Grass

All six post set and elevation confirmed.

Cloud Sky Road surface Tree Asphalt

Next up was to reestablish the property line between my neighbor. His driveway grew by 6'.
The break in the rock barrier shows a hole where the front fence will terminate (45º back). 14 holes for the front portion of the cleared area. A total of 140' of 48" fencing with 2" angle iron panels each with 5/16" welded wire mesh will finish up the front fence.
Plant Agriculture Grass Groundcover Landscape

Back to the privacy fence. 1/8"x 2"x 2" angle iron will be used to frame in between the posts. The plan is to insert cold rolled corrugated panels inside the 2" angle frame. 1/8" x 1" x 1" angle will be used on the inside to capture the panels for a no screw application. The bottom (inside) 1"x1" angle will be in two 30" sections with a middle section of 37.5". These lower sections will be secured with #14 Tek screws. The upper section will be welded in. The idea is to be able to remove and replace any damaged panel without grinding or cutting.
Back to the 2" main frame details.
The verticals were notched on the iron worker. The first of three notches. The second notch takes out the thickness of the material and the third notch takes off the tip to make clearance for the inside corner (radius) of the un-notched top and bottom rails.
Automotive tire Bumper Automotive exterior Floor Motor vehicle

Right and left ends. Here you can see all three notches completed.
Road surface Wood Asphalt Automotive tire Floor

The group ready for welding onto the posts.
Wood Line Red Gas Composite material

The inside top shows the 1" angle sandwiching the corrugated between both smaller and larger angle. The corrugated is 7/8" thick so with the 1/8" thick 2" angle the inside measurement comes to 1-7/8" making the 1" inner angle a perfect match for a flush finish.
Sky Wood Rectangle Gas Tints and shades

A detail of the Botton (removable) angle.
Automotive tire Wood Tread Rim Synthetic rubber
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firestopper
Yesterday morning I wiped the light oil film off the sheets using purple power degreaser.
The idea of the privacy fence was to keep the front of the shop somewhat concealed. You can see the fence ends where the house begins. More importantly, you no longer see the rear of the property where the wash rack is from the road.
Sky Plant Tree Land lot Grass

The inside between the apron and fence will be graded to encourage draining along the concrete all the way to the street. I will rip-rap with river rock prior to importing 1"- Coronado brown gravel.
Sky Road surface Tree Asphalt Wood

I like the detail of the fence. Most corrugated fences screwed onto stringers welded over the posts (way easier) for a continuous corrugated panel look. I wanted posts and frames exposed for a custom look.
It really helps to have your shop, mixer , and forklift at your job site.(y)
Notice the three lower 1" angle sections screwed down per panel. using three sections should allow to only remove one section to re-sheet in the event of damage.
Sky Road surface Shade Asphalt Fence

Next up after cleaning was to initiate the rusting.
Automotive tire Gas Building Machine Metal

Using a hand held pump sprayer a mixture of hydrogen peroxide, vinegar, and salt makes for inexpensive rusting agent.
Handwriting Wood Rectangle Font Gas

Three applications later using a fine fog mist you get this.
Sky Land lot Plant Tree Natural landscape

inside.
Sky Outdoor bench Plant Tree Road surface

Sky Plant Property Wood Land lot

Now to clean out the front holes after the javelina have been trying to fill back in.
Turn and Burn!
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OkDually
firestopper said:
Yesterday morning I wiped the light oil film off the sheets using purple power degreaser.
The idea of the privacy fence was to keep the front of the shop somewhat concealed. You can see thence ends where the house begins. More importantly, you no longer see the rear of the property where the wash rack is from the road.
View attachment 656578
The inside between the apron and fence will be graded to encourage draining along the concrete all the way to the street. I will rip-rap with river rock prior to importing 1"- Coronado brown gravel. View attachment 656579
I like the detail of the fence. Most corrugated fences screwed onto stringers welded over the posts (way easier) for a continuous corrugated panel look. I wanted posts and frames exposed for a custom look.
It really helps to have your shop, mixer , and forklift at your job site.(y)
Notice the three lower 1" angle sections screwed down per panel. using three sections should allow to only remove one section to re-sheet in the event of damage.
View attachment 656580
Next up after cleaning was to initiate the rusting.
View attachment 656581
Using a hand held pump sprayer a mixture of hydrogen peroxide, vinegar, and salt makes for inexpensive rusting agent.
View attachment 656585
Three applications later using a fine fog mist you get this.
View attachment 656582
inside.
View attachment 656584
View attachment 656583
Now to clean out the front holes after the javelina have been trying to fill back in.
Turn and Burn!
Click to expand...
Awesome job!
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mp06011999
Sharp! (y)

I'm imagining large metal cutouts of desert animals mounted a little off the surface of that fence :unsure:
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firestopper
A little update on the flagpole.
A change in direction in the initial design. After a little back and forth communications with forum member Ben A Gonna, he planted a seed on break over feature that would allow the pole to be laid over for halyard or truck (pulley) maintenance. This got me thinking on a counterweighted pivoting pole. The existing pier will still work so Im heading that direction. A fair amount of calculations need to be done so that the pole weight will remain neutral during the entire tilt.
On the flagpole finial (ball and truck assembly) I was able to source a truck for just under $100. The truck swivels 360º to allow for wind directional changes preventing Old Glory from wrapping around the pole. Once I received the truck I was disappointed with the pulley application.

They did use a stainless roll pin to secure the aluminum pulley to the truck, however I didn't care for the sloppy play and lack of smoothness on the pulley.
Tool Gas Auto part Blade Metal

Removed the roll pin and machined a stainless axel shaft for upgraded ceramic precision bearing.
I keep all sorts of bearings on the shelf for situations like this.
Green Cutting mat Gas Engineering Pattern

Some lathe work making the axel shaft. After turning the main diameter to press fit the bearing inner race, I turned the major diameter for threading.
Machine tool Engineering Gas Machine Metal

The nyloc nut fit nicely.
Machine tool Cylinder Gas Engineering Machine

I then opened up the aluminum pulley to press in the new bearings. Annular cutter makes a large round hole for the use of a boring bar for final ID.
Machine tool Engineering Gas Metalworking Auto part

The Annular cutter got me close so only a cleanup pass was required.
Machine tool Milling Gas Engineering Machine

Pressed in the new ceramic bearings. Ready for reassembly of the truck. Only one side of the truck required a larger hole for the new axel.
Cutting mat Tool Gas Circle Jewellery

Next was the actual final or the ball. 6" ball should look good 30' up and mounted to the top 4.5"OD section of sch. 40.
A small section of 1" tube was welded on and a 1/2-13 bolt bead was turned on the lathe to allow to slip into the tube for welding. The ball was then primed with acid blowing primer. This will be the only portion the the flagpole that gets painted. It will be copper using that same patina verde finish.
Musical instrument Wood Table Gas Sports equipment

The ball screws into the top of the rotation truck assembly.
Tire Wheel Ball Natural foods Vehicle

The truck assembly has 1.25 NPT threads for mounting. A cap plate will be made to weld on a threaded coupling with only 1/4" of it proud.
More to come...
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firestopper
Using the lathe I was able to turn the OD the ID to accept the coupler. The OD fits nicely over the beveled factory finish of the upper pipe.

Another larger Annular cutter at work saving time eliminating step drilling.
Blue Machine tool Milling Metalworking Engineering

Final bore.
Milling Machine tool Engineering Gas Auto part

The coupling fits snug and will only protrude 1/4". With the plate/coupling welded on the top of the pole, the truck can be replaced by unthreading the assembly.
Blue Automotive tire Machine tool Gas Cylinder

More on the flagpole later.

It's been a little hard this month for my wife and I. Our last two remaining German squatters turn 11 next month and my girl is quickly approaching her end of life stage. We recently went through this loosing two of them 28 days apart.

Her name is Valkyrie and she's sweetheart of a girl. What a blow to my heart. This girl is my shadow (literally) for those of you familiar with GSD's. Everyday is her birthday at this point. When the time comes the vet will make a final house call to prevent unwanted stress during her final time on earth. We did this with our other two and it was a peaceful sendoff. He brother Hercules' will be able to mourn her passing along with us.

Dog Dog breed Wood Carnivore Fawn

Have a safe and productive day DP brethren.

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firestopper
OkDually said:
Awesome job!
Click to expand...
Thank you sir! I appreciate you always visiting the Fallout Shelter.
mp06011999 said:
Sharp! (y)

I'm imagining large metal cutouts of desert animals mounted a little off the surface of that fence :unsure:
Click to expand...
Thanks amigo!
No Coyote art for me but I do plan on some designs for other front yard features. You'll have to tune in as Im still mulling ideas in my peabrain...
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mp06011999
firestopper said:
Thank you sir! I appreciate you always visiting the Fallout Shelter.


Thanks amigo!
No Coyote art for me but I do plan on some designs for other front yard features. You'll have to tune in as Im still mulling ideas in my peabrain...
Click to expand...
Part of me wants to see Wile E. Coyote chasing the Road Runner, with puffed smoke and all - lol.

Jokes aside, I'm more a fan of basics like cactus, boulders, maybe a lizzard. I still wanna make stone-filled rebar cactus to replace anything left growing in the yard. Just haven't yet.
Sky Plant Wood Tree Sculpture


Just saw this and think it's cool.
Plant Land lot Rectangle Road surface Grass


Just sharing ideas....

As always, you do nice work (y)
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OkDually
firestopper said:
It's been a little hard this month for my wife and I. Our last two remains German squatters turn 11 next month and my girl is quickly approaching her end of life stage. We recently went through this loosing two of them 28 days apart.

Her name is Valkyrie and she's sweetheart of a girl. What a blow to my heart. This girl is my shadow (literally) for those of you familiar with GSD's. Everyday is her birthday at this point. When the time comes the vet will make a final house call to prevent unwanted stress during her final time on earth. We did this with our other two and it was a peaceful sendoff. He brother Hercules' will be able to mourn her passing along with us.
Click to expand...
I'm positive the GSD's appreciate their life you gave them on this earth. Their journey across the bridge will be peaceful and your loyalty will give solace in the last days.
They in turn have given you many, many memories that will live on.
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It's tough losing your furry friends.
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mp06011999
firestopper said:
...
It's been a little hard this month for my wife and I. Our last two remains German squatters turn 11 next month and my girl is quickly approaching her end of life stage. We recently went through this loosing two of them 28 days apart.

Her name is Valkyrie and she's sweetheart of a girl. What a blow to my heart. This girl is my shadow (literally) for those of you familiar with GSD's. Everyday is her birthday at this point. When the time comes the vet will make a final house call to prevent unwanted stress during her final time on earth. We did this with our other two and it was a peaceful sendoff. He brother Hercules' will be able to mourn her passing along with us.

View attachment 656604
Have a safe and productive day DP brethren.
Click to expand...
Sad. I try and focus on the fact that a sad end of life means there was a happy life. Easier said than done when it happens.

I feel for you.

My inability to handle loss of a loved one kept me from ever having another pet and is part of the reason for never having kids and trying to resist the love of a good woman for years. I know, even sadder than loss. In that regard, I am most definitely broken.

Kudos for all you did for each other and again, my heart goes out to you.
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