Absolutely amazing the stuff that you do.
The Fallout shelter 14'X40'X80'
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.
A last look of the old shop.
After pulling a large Palo Verde tree and relocating a 40' sea container I was ready to layout the new pad.
Forming and importing dirt as well as laying out all the anchor bolts for the 10 columns.
The night before the 3am pour.
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.
The power finisher doing its magic.
Finished up around noon for a 9 hour day. I kept the water on for 7 days to counter the hot days.
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.
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.
Between the drivers crab style fork lift and my Hyster, we made short work of staging the "red iron".
More to follow.
921 - 934 of 934 Posts
Thank you sir! Last week I was explaining to my neighbor the fence panel design I had in my head. He couldn't envision it but he came over yesterday while I was welding in those panels, he really liked it. The end wings will add flair to the overall project.Another awesome project. It amazes me how some people can envison something, create it and it ends up in a spectacular masterpiece. Sir, you have that gift. Someday maybe I will find out what my gift is.
Keep the projects coming.
Hint, I have a special design for those end post caps.
Thank you for the generous compliment brother...
Confession, panel number 9 was 5/8" short! How this happened IDK other than my dyslexia Ive been blessed with my entire life. Anyway, I had to carry that panel back to the shop and add 5/16" angle slivers to each weld wing then carry it back some 80 yards.
Most fellas would have added 5/8" to each tab on one end but NO!!! Mr.OCD had to keep that 119" panel centered. After the welds were blended the now 3-5/16" tabs are not noticeable.
12'x6' Slide Gate
This gate was built to match the main entrance gate (motorized) I built a couple of years ago. This gate leads to the back section of the property were I installed a tall pergola and two post lift.
This gate is manually operated.
The frame was built from 14ga 2"x4" and the lower wheel boxes were also frenched in keeping the bottom of the gate as close to the base as possible.
This frame was bigger than the jig table so rolling stands were used.
![Wheel Engineering Composite material Gas Machine]()
Those strong hand 90º magnets really help to keep things square.
![Wheel Tire Automotive tire Motor vehicle Automotive design]()
The wheels set into the tubing and welded in. The lower gap came to 2-3/4" using this method.
![Tire Automotive tire Asphalt Road surface Automotive lighting]()
Using 2"x2" angle to frame in the inside of the main frame gave the corrugated sheets a nice place to rest.
1"x1" angle captured the sheets from the inside. These angle sections (top and bottom) are only tacked in using 1/2' beads. This will make it easier to replace sheets in the event of damage.
![Wheel Tire Vehicle Motor vehicle Wood]()
The top angle guide roll fits in-between two precision bearings (guide pinch roller) and keeps the gate plumb as well.
The ends are capped to stop the gate from over traveling.
![Wood Mode of transport Gas Engineering Automotive exterior]()
Using pipe to roll the heavy gate off the trailer.
![Sky Road surface Tree Asphalt Wood]()
With the 1"x1" angle secured to the concrete we now have a track to roll on.
![Sky Tire Tree Road surface Shade]()
Whoever poured the concrete failed to get it perfectly level. I remember having issues with all the gates (4) I built for this property. I get frustrated because I know how easy it is to achieve this if levels are used prior to pouring. Oh
well....
![Sky Rectangle Road surface Asphalt Wood]()
The outside has the matching mountain cutout as the front motorized gate. Good thing I kept the DXF file for the plasma table.
![Sky Road surface Asphalt Shade Rectangle]()
Hard to see from this angle but if you were to stand directly in from of the gate, you'd notice the vertical lines of the corrugated do not match the vertical reveals of the walls. The same crew that poured the concrete laid up the crooked walls.
You can now see the 2" angle frame that secures the corrugated. The decorative mountain is held off 3/4" from the angle frame to add depth.
Not all jobs give me a satisfying feeling but I need to accept some trades don't care as much.
Moving on....
This gate was built to match the main entrance gate (motorized) I built a couple of years ago. This gate leads to the back section of the property were I installed a tall pergola and two post lift.
This gate is manually operated.
The frame was built from 14ga 2"x4" and the lower wheel boxes were also frenched in keeping the bottom of the gate as close to the base as possible.
This frame was bigger than the jig table so rolling stands were used.
Those strong hand 90º magnets really help to keep things square.
The wheels set into the tubing and welded in. The lower gap came to 2-3/4" using this method.
Using 2"x2" angle to frame in the inside of the main frame gave the corrugated sheets a nice place to rest.
1"x1" angle captured the sheets from the inside. These angle sections (top and bottom) are only tacked in using 1/2' beads. This will make it easier to replace sheets in the event of damage.
The top angle guide roll fits in-between two precision bearings (guide pinch roller) and keeps the gate plumb as well.
The ends are capped to stop the gate from over traveling.
Using pipe to roll the heavy gate off the trailer.
With the 1"x1" angle secured to the concrete we now have a track to roll on.
Whoever poured the concrete failed to get it perfectly level. I remember having issues with all the gates (4) I built for this property. I get frustrated because I know how easy it is to achieve this if levels are used prior to pouring. Oh
well....
The outside has the matching mountain cutout as the front motorized gate. Good thing I kept the DXF file for the plasma table.
Hard to see from this angle but if you were to stand directly in from of the gate, you'd notice the vertical lines of the corrugated do not match the vertical reveals of the walls. The same crew that poured the concrete laid up the crooked walls.
You can now see the 2" angle frame that secures the corrugated. The decorative mountain is held off 3/4" from the angle frame to add depth.
Not all jobs give me a satisfying feeling but I need to accept some trades don't care as much.
Moving on....
Crowns.
An update to the front decorative fence.
I sourced a 74 pound section of sch. 80 5-5/16" pipe. It was a remnant and sold for .59/pound.
The Ellis really does a nice job cutting straight. Six 1" wide rings were cut.
![Automotive tire Motor vehicle Gas Automotive wheel system Machine]()
Using a deep thought portaband saw I carefully cut small sections. These sections were then profiled to fit inside the ring. The remaining section was the cut in half creating two 3" sections. You can see the layout on the table at the base of the crown.
![Motor vehicle Automotive design Rim Automotive tire Engineering]()
After grinding and blending I had one of three done.
![Hood Wood Automotive tire Motor vehicle Font]()
Rinse and repete x2. The two bottom crowns are welded to base plates while the top crown will be welded directly.
![Plumbing fixture Gas Tap Art Engineering]()
The front decorative fence got those termination wings I mentioned in the original post of this project.
![Plant Wood Sky Road surface Tree]()
The main entrance wing was treated to the house numbers and the Rocking K logo our community is named after.
![Sky Cloud Land lot Asphalt Wood]()
The last crown was welded on top of the lamp post for a finishing touch. This lamp has been crown less for 34 years. In this photo, a keen eye can pick up all those parallel lines and vertical lines that can only come from building square, level and plumb. This is what my eyes see when I look at things.
![Plant Wood Door Wall Terrestrial plant]()
Looking from the front door.
![Cloud Plant Sky Automotive tire Biome]()
The story behind the Crown design.
Many years ago I discovered an old Episcopal church built back in the late 1900's. It's an old adobe construction with heavy timber. The entire campus was adorned with old school wrought iron obviously hand crafted by blacksmiths.
I was moved by this simple cross design and filed it away in the depths of my peabrain. The fact that I recalled this design after decades tells me it was meant to be. A subtle tribute to our savior.....
Thanks for visiting and be well brethren.
Peace...
An update to the front decorative fence.
I sourced a 74 pound section of sch. 80 5-5/16" pipe. It was a remnant and sold for .59/pound.
The Ellis really does a nice job cutting straight. Six 1" wide rings were cut.
Using a deep thought portaband saw I carefully cut small sections. These sections were then profiled to fit inside the ring. The remaining section was the cut in half creating two 3" sections. You can see the layout on the table at the base of the crown.
After grinding and blending I had one of three done.
Rinse and repete x2. The two bottom crowns are welded to base plates while the top crown will be welded directly.
The front decorative fence got those termination wings I mentioned in the original post of this project.
The main entrance wing was treated to the house numbers and the Rocking K logo our community is named after.
The last crown was welded on top of the lamp post for a finishing touch. This lamp has been crown less for 34 years. In this photo, a keen eye can pick up all those parallel lines and vertical lines that can only come from building square, level and plumb. This is what my eyes see when I look at things.
Looking from the front door.
The story behind the Crown design.
Many years ago I discovered an old Episcopal church built back in the late 1900's. It's an old adobe construction with heavy timber. The entire campus was adorned with old school wrought iron obviously hand crafted by blacksmiths.
I was moved by this simple cross design and filed it away in the depths of my peabrain. The fact that I recalled this design after decades tells me it was meant to be. A subtle tribute to our savior.....
Thanks for visiting and be well brethren.
Peace...
20 amp circuit
Decided to extend a 20A circuit to the new fence. Im hoping to string Christmas lights along the fence line and thought having a dedicated circuit would be convenient.
It took longer to trench using a jackhammer than to run the conduit, pull #12 and backfill.
![]()
When the post was set I didn't think about running a sweep in the mud so the jackhammer ate a channel along the concrete.
I was able to get the final riser nice and plumb along the post. This required a slight offset using a heat gun.
![]()
The box was secured to the post at the same height as the lower weld clip.
![]()
A better view of the offset riser.
![]()
Like it never happened except my back said it did!
![]()
The receptacle I tapped into is protected by GFI.
Decided to extend a 20A circuit to the new fence. Im hoping to string Christmas lights along the fence line and thought having a dedicated circuit would be convenient.
It took longer to trench using a jackhammer than to run the conduit, pull #12 and backfill.
When the post was set I didn't think about running a sweep in the mud so the jackhammer ate a channel along the concrete.
I was able to get the final riser nice and plumb along the post. This required a slight offset using a heat gun.
The box was secured to the post at the same height as the lower weld clip.
A better view of the offset riser.
Like it never happened except my back said it did!
The receptacle I tapped into is protected by GFI.
With the front metal work in progress, I seemed to pick up some work in the hood.
Pool broom and net brackets
These brackets will help secure a pool net and a pool broom along a wall.
![]()
Pedestrian gate
Same house gets a new gate with a corrugated panel.
Using the M18 8" metal circular saw I was able to trim to proper height. I've cut stacked material without issues but this is the first time I cut a singe 24 ga. sheet. I was apprehensive because the blade is somewhat course and I thought it would distorted the cut but as long as you keep the saw flat and a conservative feed it made short work of the corrugated.
![]()
Address Marquee
The third project for the same house is am address marquee.
I plasma cut all the 1/8" plate into 8"x14" panels. I then laid out all center lines and transferred the same lines onto the corresponding house numbers. Each number received two drilled holes along the center line. These holes were then transferred onto the base plates. Small sections of 1/4" solid round stock were cut into 1.250" lengths. The drill bit used was slightly smaller than the rod so a tap into the base plates held them just sub-flush on the backside. This provided a nice application of a rosette weld aka plug weld. By leaving the rod sub flush allows for grinding smooth and retain strength. Once the rods were welded to the base plate the numbers were tapped onto the protruding rods and the same application was followed.
![]()
Here you can see the the eight being place onto the welded rod. The Torpedo level made sure the numbers were level on both directions prior to plug welding.
![]()
A hot rosette weld does the trick.
![]()
Followed by grinding and blending.
![]()
With the four panels lined up, all four numbers line up nicely. Using a centerline also kept all the rods inline.
![]()
Welding two 1.5" x 1.5" 14 gauge square tubing completes the marquee. The top of the tubing were also capped off with steel and blended to look solid.
A piece of rebar was welded to the base that will be set in concrete. The first blank panel will be 2" above grade when done.
![]()
A slight angle shot.
![]()
Ill use peroxide, vinegar, and salt in a hand held pressure bottle to crate a rust patina on both this and the gate.
A low voltage light will also be installed a few feet in front of the address marquee to cast shadows from the protruding numbers.
Clean application using plug welds. You can see the completed gate in the back round.
![]()
Have a great hump day!
Pool broom and net brackets
These brackets will help secure a pool net and a pool broom along a wall.
Pedestrian gate
Same house gets a new gate with a corrugated panel.
Using the M18 8" metal circular saw I was able to trim to proper height. I've cut stacked material without issues but this is the first time I cut a singe 24 ga. sheet. I was apprehensive because the blade is somewhat course and I thought it would distorted the cut but as long as you keep the saw flat and a conservative feed it made short work of the corrugated.
Address Marquee
The third project for the same house is am address marquee.
I plasma cut all the 1/8" plate into 8"x14" panels. I then laid out all center lines and transferred the same lines onto the corresponding house numbers. Each number received two drilled holes along the center line. These holes were then transferred onto the base plates. Small sections of 1/4" solid round stock were cut into 1.250" lengths. The drill bit used was slightly smaller than the rod so a tap into the base plates held them just sub-flush on the backside. This provided a nice application of a rosette weld aka plug weld. By leaving the rod sub flush allows for grinding smooth and retain strength. Once the rods were welded to the base plate the numbers were tapped onto the protruding rods and the same application was followed.
Here you can see the the eight being place onto the welded rod. The Torpedo level made sure the numbers were level on both directions prior to plug welding.
A hot rosette weld does the trick.
Followed by grinding and blending.
With the four panels lined up, all four numbers line up nicely. Using a centerline also kept all the rods inline.
Welding two 1.5" x 1.5" 14 gauge square tubing completes the marquee. The top of the tubing were also capped off with steel and blended to look solid.
A piece of rebar was welded to the base that will be set in concrete. The first blank panel will be 2" above grade when done.
A slight angle shot.
Ill use peroxide, vinegar, and salt in a hand held pressure bottle to crate a rust patina on both this and the gate.
A low voltage light will also be installed a few feet in front of the address marquee to cast shadows from the protruding numbers.
Clean application using plug welds. You can see the completed gate in the back round.
Have a great hump day!
^ Nice work. Reminds me of when I instructed a bunch of our employees to start taking down the company logo signs on the building as we had just sold the property. The employees started by taking down the address numbers first until I stopped them, saying, you know the address isn't changing.
Sometimes minimum wage is too much
until I stopped them, saying, you know the address isn't changing. Sometimes minimum wage is too much
Thank you sir!
Yes laying out always helps me to achieve what my "minds eye sees" when done. Many times when Im approached with a project my mind goes wild as I'm speaking with the person I'm working for. I see (in my head) many designs and it helps me come up with a design in a relative short time. It's putting it all together where the fun starts for me. The challenge is to explain to the person what I propose to build. Typically they follow along but when it's done they say something like I wasn't expecting this or that (in a good way). I tried to explain the round stock and proud numbers (floating appearance) but I was getting a blank stair.
Im sure he will be pleased when its in the ground.Thanks for the visit brother!
Hi,
The last panel will remain blank. It's only there to fill in space to allow the last number to be raised up off the ground. There will be a 2" gap between the bottom panel and the grade. The street name is "South Avenida de Pina" so it would be too small to read to fit it in. I considered a southwest design but he might not appreciate those as I do.
Thanks for the nice words. Anyone, and I do mean anyone can achieve this level of work with time. the secret is to simply care. I don't care about the payday as much as I care about the challenge and finished product. Im blessed to have found something I was born to do. We all have a gift, and by gift I mean a passion for something. Discovering ones passion is were the gift part comes in. Ive worked with very intelligent people who didn't care. I had no real appreciation for them because as the saying goes "its not how much you know... its about how much you care".
Thank you for visiting as well.
Oh brother your statement about the address being taken down had me in stitches! Thank goodness I wasn't drinking coffee when I read it!^ Nice work. Reminds me of when I instructed a bunch of our employees to start taking down the company logo signs on the building as we had just sold the property. The employees started by taking down the address numbers first
Sometimes minimum wage is too much
be well, and its always good to hear from you.
In closing, I want to explain why I post my metal works. My hope is that someone finds the work interesting and perhaps tries it out. I share techniques Ive found to work well over the years, but also share in hopes of learning something new by anyone who wants to add feedback (good or bad). Everyday I lean something very important that applies to my work and or and life. I value all of you even though we've never met.
God bless and keep on keeping on!
You're welcome. Wife says my sense of humor is what she was first attracted to so I must be doing something right - lol.Thank you sir!
Yes laying out always helps me to achieve what my "minds eye sees" when done. Many times when Im approached with a project my mind goes wild as I'm speaking with the person I'm working for. I see (in my head) many designs and it helps me come up with a design in a relative short time. It's putting it all together where the fun starts for me. The challenge is to explain to the person what I propose to build. Typically they follow along but when it's done they say something like I wasn't expecting this or that (in a good way). I tried to explain the round stock and proud numbers (floating appearance) but I was getting a blank stair.
Thanks for the visit brother!
Hi,
The last panel will remain blank. It's only there to fill in space to allow the last number to be raised up off the ground. There will be a 2" gap between the bottom panel and the grade. The street name is "South Avenida de Pina" so it would be too small to read to fit it in. I considered a southwest design but he might not appreciate those as I do.
Thanks for the nice words. Anyone, and I do mean anyone can achieve this level of work with time. the secret is to simply care. I don't care about the payday as much as I care about the challenge and finished product. Im blessed to have found something I was born to do. We all have a gift, and by gift I mean a passion for something. Discovering ones passion is were the gift part comes in. Ive worked with very intelligent people who didn't care. I had no real appreciation for them because as the saying goes "its not how much you know... its about how much you care".
Thank you for visiting as well.
Oh brother your statement about the address being taken down had me in stitches! Thank goodness I wasn't drinking coffee when I read it!
be well, and its always good to hear from you.
In closing, I want to explain why I post my metal works. My hope is that someone finds the work interesting and perhaps tries it out. I share techniques Ive found to work well over the years, but also share in hopes of learning something new by anyone who wants to add feedback (good or bad). Everyday I lean something very important that applies to my work and or and life. I value all of you even though we've never met.
God bless and keep on keeping on!
I try and learn from every situation. Sometimes, I even learn the right things. But yea, it's why I read this thread, even if most of what you do is outside of my wheelhouse. And it's why I seem to recall so many situations. Either for a lesson or just the humor of it all. And I seem to keep getting more inquisitive with age. I thought I was supposed to shut that brain down and just rock in my chair - lol, NEVER!
Keep up the awesome work and tutorials. Know too that a lack of comments does not mean a lack of views
Happy Memorial Day weekend!
921 - 934 of 934 Posts
