DIY Network

Treating the Surface of the Metal The barstool metal surface is ground to perfection. From "Freeform Furniture" episode DFFF-110

In this segment host Amy Devers demonstrates how to grind down the metal surface, use a random orbital sander to sand off any surface discoloration and how to do the gun bluing.

advertisement

	Host Amy Devers demonstrates how to grind and sand the metal and how to apply the gun blue.
	Notice the shine of the treated barstool metal.

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

Treating the Surface of the Metal

1. Use the angle grinder to grind down all of the welds so that they are flush with the surface of the metal. Just a few passes over each of the welds with the grinder (figure A) creates a smooth, almost fluid finish where you can hardly see where one piece of metal leaves off and the other starts.

   Tip: When you are selecting a grit for the grinder, it is always important to match the right grit with the right density of material--whether it's steel, wood, or even plastic. An 80-grit grinding disc is just coarse enough to take down the welds. Just as important as selecting the right grit, is to keep a steady hand. The grinders are fast and powerful. One false swipe and you can easily gouge the steel through the wall of the tube.

2. Once all the welds are ground down, switch over to the random orbital sander and polish the entire surface of the barstool (figure B) removing any discoloration or blemishes giving the steel a nice, uniform surface before you apply the patina.

3. Use a 120-grit sanding disc. The random orbital sander spins in the center and it is random because it vibrates constantly so you don't get a swirl/scratch pattern.

4. Clean the residue from the sanding with a clean rag and a simple degreaser (figure C) that is available at hardware stores. Once it is clean and free of dust, you want to apply a special patina called a gun blue.

   Note: Gun blue is a natural acidic oxide that is used to darken steel. You can get it online or at any metal supply store. It not only helps to protect the steel from rust, it will turn it a nice deep blue color.

5. Lay some cardboard out to protect the table from the chemicals. Wear gloves and use a respirator because it is toxic.

6. Pour some of the gun blue into a plastic cup. Take synthetic steel wool and dip it in the gun blue and apply it to the surface along the length of the steel (figure D).

   Note: Using a mild steel as opposed to a stainless will prevent the gun blue from penetrating the alloys of stainless steel in the same way that it absorbs into the mild steel.

7. Make sure you don't scrub with too much pressure or you might scratch the metal which can often happen when rubbing steel together. When it dries it will have a blackish-blue sheen to it. It usually takes about two to three applications for the chemicals in the gun blue to oxidize the metal enough to get a dark hue.

   FYI: Gun blue was put on the market back in the 1930's for blackening firearms, which is how it got its name.

8. Finish it up with a final coat of wax.

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