Metal Staircase & Water-Slide

Due to Travel and the Hot Las Vegas Summer … I have not been able to get out into the Metal Workshop as much as I have wanted in the last few months …

Therefore, decided to show some past metal projects done a few years ago …

One is a Metal Staircase done with some friends of mine up in North Dakota, and the other is of a Water-Slide in the ‘Lake Country’ of Minnesota.

First Staircase SolidWorks CAD Concept Rendering

First Staircase SolidWorks CAD Concept Rendering

My friends built a Lake Cabin and came up with a Metal Staircase design for it.

Metal_Stair_Concept

Metal Step Frame Drawn with an Older Version of SolidWorks

We refined the design and came up with a Single ‘Spine’ Beam Stairway concept.

Staircase Concept Showing the Single 'Spine' Beam Concept with Hidden Bolts

Staircase Concept Showing the Single ‘Spine’ Beam Concept with Hidden Bolts

Once we had an idea of what we wanted, I created individual drawings of each of the parts needed.   SolidWorks CAD software made finding the correct unusual angles & curves a breeze.  Some of the curved parts I cut out on a WaterJet down here in Las Vegas and shipped them up to North Dakota.

Randi working on one of the Metal Stair Frames

Randi working on one of the Metal Stair Frames

Once the parts arrived, I put a small Inverter  D/C TIG Welding Machine in my suitcase and flew up to North Dakota where we built the Staircase onsite.

Randi Became Quite the Talented Metalworker & Painter During the Project

Randi Became Quite the Talented Metalworker & Painter During the Project

Somewhere along the design phase we found that we would be able to hide the upper staircase mount inside the wall on top of a huge wood beam creating a look that the center metal spine was just resting against the wall.

Tack Welding the Mounting Plate in the Beam to Prepare for Final Welding

Tack Welding the Mounting Plate in the Beam to Prepare for Final Welding

I drilled holes in a thick metal plate and put the heavy bolts through it and then welded the ends of the bolts to the plate inside the metal beam.  Then once the metal plate was tacked in place I went back and ground out the edges of the plate into a full bevel so I could create a full penetration weld with 7018 DC Welding Rod from the back of the plate forward for a very strong weld.

Checking the Fit-Up of the Beam Mount Before Final Welding

Checking the Fit-Up of the Beam Mount Before Final Welding

We lifted up the metal beam and then Randi and his wife Carma held the beam by themselves, with the help of some scaffolding, while I attached the bolts to the hidden ‘Very Strong’ metal mount placed on top of a huge wood beam.

Putting Nuts on the Bolts Slid Through the Holes in the Hidden Staircase Mount

Putting Nuts on the Bolts Slid Through the Holes in the Hidden Staircase Mount

With Much Relief the main ‘Spine’ beam was installed without hurting anyone.

Center Metal 'Spine' installed to Look as if Leaning Against the Wall

Center Metal ‘Spine’ installed to Look as if Leaning Against the Wall

The Next Step was to bolt on each Step Frame and then Level before tightening.

Stairs08

Randi Bolting on the Individual Step Frames to the Center ‘Spine’ Beam

Once Level the Step Frames Were Secured with Hidden Bolts Inside

Once Level the Step Frames Were Secured with Hidden Bolts Inside

Testing the Stairs after all the Bolts were Tightened

Testing the Stairs after all the Bolts were Tightened

Finished Staircase Frame Ready for Stair Planks and Railings

Finished Staircase Frame Ready for Stair Planks and Railings

Showing the Latest Fashion in Welding Helmet Head Hair

Showing the Latest Fashion in Welding Helmet Head Hair

Sometime around 1AM the night before I flew back to Las Vegas we finished welding the railings in place.   We were able to weld inside because we used TIG welding that does not create sparks as other forms of welding do … However, Randi stood fire watch and honestly we were too tired to care. *Laughing*

Later my friends sent me photographs of the finished painted Stairs & Railings.

Welding the Railing on the Upper Inside Cabin Balcony

Welding the Railing on the Upper Inside Cabin Balcony

After I flew home, they used tightly stretched Metal Cables inside the Railings.

View from the Upper Inside Balcony of the Finish Railings

View from the Upper Inside Balcony of the Finish Railings

It was a fun project to design ‘long distance’ together and successfully build.

What made it even more fun was we didn’t have a design time limit, so we could take our time, and we didn’t have to worry about any labor cost because my friends and I were the ‘Free Labor’ … with the only cost being materials.

View of Inside Cabin Balcony from Below

View of Inside Cabin Balcony from Below

The Design allows people behind the stairs to still see an open view of the lake.

The Finished 'Open' Stairs do not Block the View of Lake

The Finished ‘Open’ Stairs do not Block the View of Lake

They have Since added a very Cool Outdoor Balcony!!

.  .  .

Another friend of mine from Minnesota wanted to build a Water-Slide.

Nate with the Completed Metal Frame for his Kid's Slide

Nate with the Completed Metal Frame for his Kid’s Slide

Nate had a Plastic Slide and wanted to turn it into a Lake Water-Slide.

Welding the Slide Frame Together before Grinding Smooth the 'Stick' Welds

Welding the Slide Frame Together before Grinding Smooth the ‘Stick’ Welds

I had a ‘Stick’ (SMAW) welding machine at the time, so we cut and bent some steel tubing and quickly welded together the slide frame, steps, and handrails.

Nate later ‘water-proof’ galvanized the metal and used plastic decking for steps.

Nate's Finished Water-Slide for His Kids

Nate’s Finished Water-Slide for His Kids

Nate later sent me photos of the Finished Water-Slide at his Lake Cabin.

Hidden Long Underwater Boards Keep Slide Stable

Hidden Long Underwater Boards Keep Slide Stable

Having a Metal Workshop Leads to some Fun Projects with Friends …

A Motley Crew Enjoying Nate's Water-Slide at the Lake

A Motley Crew Enjoying Nate’s Water-Slide at the Lake

— CHEERS …

.  .  . 

Advertisements

Leave a comment

Filed under PROJECTS

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s