We have the best neighbors and like to exchange help on household projects.
We needed some concrete work done on our pool & wall, and our neighbor was building a backyard BBQ area and needed Stainless Steel Doors.
( He owns a Custom Concrete & Stone Business )
He showed me the concrete block BBQ structure so I could measure the openings that required two single doors and one set of double doors.
The plan was to cover the BBQ concrete block with Stone approximately 1.5″ thick; therefore, I needed to come up with a design to hold the Stainless Steel doors out far enough to match the thickness of the stone.
Decided to use stainless angle to create frames and use 3DP for hinge parts …
Created the BBQ Door designs using SolidWorks CAD Software …
Matched the top of the handles the same distance from the top of doors …
Once I had the doors figured out … Made a quick BBQ area concept drawing.
Showed the BBQ area concept designs to our neighbor and he liked them …
Next step was to refine the Sheet Metal bends and hole locations using the ‘Sheet Metal’ feature which is included with SolidWorks CAD Software.
Created Sheet Metal Flat-Patterns to make sure the Stainless Steel Fabrication shop would be able to Cut the doors with a CNC Laser or shear.
After the designs were given to McClure Stainless – Metal Fabricators in Las Vegas – I was then able to concentrate on the 3DP Hinge units.
Came up with a design that used a combination of 3D Printed ABS and Stainless Steel fasteners ( Nuts, Bolts, Screws ) …
The BBQ unit required a 1/8″ gap around the doors for air flow, so I used a pin hinge and was able to test the turning diameter in SolidWorks.
I knew the door’s sheet metal bend radius when received the finished Stainless doors from McClure Stainless, so adjusted my SolidWorks bends to match the bend radius of McClure’s press brake’s tooling.
BTW ~ McClure Stainless, LLC made the doors very fast & great workmanship!!
Was also able to test the maximum angle the doors could be opened.
Part of the Hinge Pin design required turning (cutting) off some of the thread on a stainless fastener to create the hinge pin end.
Made a quick fixture to hold the stainless screws in my Metal Lathe’s jaws.
Purchased the Door handles from LOWES to match the BBQ’s main handle.
Decide it would be faster & easier to drill the holes myself, and I wanted all the doors to have the same hole locations, so I 3D-Printed a punch guide for marking where to drill the holes in the bottom and top of the doors.
The handles purchased from LOWES were designed for thicker wood, so I 3D-Printed spacers for inside the doors to allow the screws to compress against the 0.050″ thick stainless steel sheet metal.
Also 3D Printed mounts to hold Ferritic Stainless Steel washers used in combination with Rare Earth Magnets pressed into 3D printed door catches screwed to the outer door frames.
Mounted the hinge pin units after I finished drilling all the holes …
I made the holes slightly larger than the hinge pin in case I needed to re-3D Print the inner mounts to adjust door alignment inside the frames.
Came up with an Upper & Lower spacer design that provided maximum coverage but also can not be viewed when door is opened and closed.
When 3D Printing little parts I like to print them in large groups to allow the filament to cool on each part before starting the next print layer.
It took over an hour to 3D Print the 16 spacers; however, once started I could work on other items out in the workshop during that time.
Still use paper drawings in my workshop, but find I am using digital .PDF drawings and eDrawings on the iPad more and more as time goes on.
Used the Miller Dynasty TIG welding machine in my workshop to make the door frames from 1.5″ x 0.125″ Stainless Steel angle …
Drilled lots of extra holes in the Stainless Steel door frames to allow for good anchor bolt/screw mounting locations on the concrete block.
After the door frames were in place our neighbor finished the stonework …
Neighbor very pleased with the results & I feel the doors look nice with stone.
In the photo below you can see one of the magnetic Ferritic Stainless catches.
Below is one of the 3DP Hinge Pin Units with the Top Cover removed.
As a bonus I got to be part of the first BBQ Cooking test!! 😜 Yum!!
As with many of my 3D Printing projects the CAD files are on GrabCAD.com
Also made a quick SolidWorks Tutorial Video showing how I used the ‘Mirror’ part feature to create mirror-image ‘clones’ of the 3D Printed (ABS) Hinge Pin part inserted into the top & bottom of the Stainless Steel BBQ doors.
Now that I know the 3D Printed ABS Hinge Pin units work with the Stainless BBQ doors, I will probably reprint them in metal at a later date just for the fun of it.
CHEERS!! Charles Marlin ( @MetalDesigner )
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