DIY Network

Deburring and More Welding The barstool cut parts are deburred and the frames are welded together. From "Freeform Furniture" episode DFFF-110

In this segment host Amy Devers demonstrates how to grind off the burrs that were created after welding the frame and seat tabs, and then she welds the frame together using a TIG welder.

And the stretchers are attached to the frame using a tack weld.

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	Host Amy Devers deburrs the welding parts and continues welding.
	Here's a low-angle view of two of the finished barstools.

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
	Figure E
	Figure F

Deburring and More Welding

1. Place the tip of each piece on the bed of the sander and slowly ease it in--this is known as deburring (figure A). You don't want to take off too much, you just want to sand off the rough edges for a smoother finish and a perfect weld.

   Note: It is a good idea to use a coarse sandpaper that is made for metal because metal is so dense it would just shred regular sandpaper.

2. Use an 80-grit sandpaper to clean up the edges.

3. Once the deburring is out of the way, you can focus your attention on welding the parts together and actually constructing the frame.

4. Lock the two parts in the welder's angle clamps which are bolted to the work table and make sure the 90-degree angle is nice and tight (figure B) to insure a pristine weld. Once it is tightly secure, you can begin welding.

   Note: The TIG welder uses a wire electrode with a metallic mineral known as tungsten at the tip. Inert gas, in this case Argon, is pumped through to the tip and creates a pocket of gas around the weld (figure C) keeping out any contaminates while the metal hardens--thereby creating a stronger weld. Just like in a car, you pump gas to conduct more energy into the TIG.

5. Turn on the gas (figure D) and then flip the switch. The key is to lay down just the right amount of filler. Filler rod is made up of a softer steel that melts easily and that makes the welding easier.

6. Weld one side and then wait 5-10 minutes for it to cool to touch and then slip it over and weld the other side.

   Safety Tip: Make sure you or anyone around you never looks directly at the blue light with your naked eye because you could risk damaging your vision.

7. When the frame itself is closer to being complete, clamp in both sides of the stools (figure E) so you can weld on stretchers for support and double check your measurements. The pieces are called stretchers because they will stretch across the sides and brace the piece together.

8. Once the frame is all welded, you need to attach the tabs so that you have something to attach the seat to later.

9. Measure where you want the tabs to go and clamp them flush with the top of the barstools so the seat will rest flat on the frame.

10. You are ready for tack welding (figure F). Tack welding is used specifically to add on hardware as opposed to filling in cracks like you did before.

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