DIY Network

Welding The welding begins the barstool project. From "Freeform Furniture" episode DFFF-110

Host Amy Devers begins the barstools by cutting the steel square tubing for the frame and then cutting the iron to make the tabs that holds the seat onto the frame.

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	Host Amy Devers begins the Barstool project by cutting and welding parts.
	These beautiful stools are the perfect complement to any bar area.

Materials:

Mild steel metal tubing
Upholstery fabric
Welding jacket
Ear plugs
Tape measure
Angle iron
Pen
Filler rod
80-grit sanding disc
Welder's angle clamp
Argon gas
Welding gloves
Clamps
Safety glasses
80-grit grinding disc
120-grit sanding disc
Rag
Degreaser
Cardboard
Rubber gloves
Respirator
Plastic cup
Synthetic steel wool
Poster board
Muslin
3/4" plywood
Electric turkey carver
2" dense foam
Spray glue
Bonded polyester batting
Cambric
Screws
Upholstery staples

Tools:

Metal chop saw
Face shield
Socket wrench
TIG welder
Disc sander
Angle grinder
Random orbital sander
Pneumatic stapler
Screw gun
Gun blue

	Figure A
	Figure B
	Figure C
	Figure D

Welding

1. The first thing you need to do is cut the steel tube down to the right sizes for the barstool on the metal chop saw. Cut all the 90-degree angles first and then the pieces that require an angle on the ends (they should be cut a little oversized--you'll go back and put the miter on it).

   Safety Tip: The metal chop saw throws off some sparks, so you need to protect yourself with long sleeves, a face shield and ear plugs.

2. Before you start cutting the pieces down with a chop saw, measure and mark your cut line.

3. Clamp the tubing down in a vice to make sure it is nice and stable and then begin to saw the steel. You need to trim down a total of 14 pieces.

   Note: Hollow tubing (figure A) is used for the barstools because it is lighter to work with and much easier to cut through. It is actually more rigid than solid steel because the material has more surface area. Hollow tubing is also less expensive at about $35 for a 15' length. You can purchase it at any industrial metal supply store.

4. With all the square tubing cut at 90-degree angles, you then need to cut each of the four brackets at 90-degrees before you change the angle on the saw. For this you need angle iron (figure B) which is a length of steel formed in the shape of an "L" or a 90-degree angle. It has any number of uses and you will be using it to make brackets.

   Note: Brackets are used to support and secure the weight of one structure to another. For the barstools, you'll be using brackets to connect the seat to the base (figure C) once you have welded the frame all together.

5. Measure the cut points for the brackets (3") and then cut each of the four brackets.

6. Use the socket wrench to set the chop saw guide to a 45-degree angle (figure D) and tighten it down. You are now ready to cut the side pieces that will support each of the stools four corners. Measure out and cut where you want the 45-degree angles. A 45-degree angle will give you a more seamless weld.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Gun Blue
Shooter Solutions
Website: www.shootersolutions.com

Miller Manufacturing Co.
Website: www.millerwelds.com

Welding Tools and Accessories
Steiner Industries
Website: www.steinerindustries.com

Smith Equipment
Website: www.smithequipment.com