3D Printed BBQ Door Hinges

We have the best neighbors and like to exchange help on household projects.

Our Neighbor’s Finished BBQ Area Project

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 )

BBQ Area BEFORE Stone was Added to Cover Concrete Block Structure

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.

Small Opening that Needed a Stainless Steel Door

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.

Outer Covering of Stone Being Installed

Decided to use stainless angle to create frames and use 3DP for hinge parts …

SolidWorks CAD Model for One of the Stainless Steel Door Units

Created the BBQ Door designs using SolidWorks CAD Software …

Testing in SolidWorks How Much the Door Would be Able to Open

Matched the top of the handles the same distance from the top of doors …

All 4 of the Stainless Steel Doors I Designed for My Neighbor’s BBQ Area

Once I had the doors figured out … Made a quick BBQ area concept drawing.

Made a SolidWorks CAD Concept Drawing of the BBQ Area

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.

Stainless Door Drawn with SolidWorks Sheet Metal Feature

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.

The SolidWorks Sheet Metal Flat-Pattern Used to Create the .DXF file

After the designs were given to McClure Stainless – Metal Fabricators in Las Vegas – I was then able to concentrate on the 3DP Hinge units.

Transparent View Showing the 3D-Printed Hinge Concept

Came up with a design that used a combination of 3D Printed ABS and Stainless Steel fasteners ( Nuts, Bolts, Screws ) …

Top Section View showing the Hinge Pin Unit and the Stainless Door

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.

Testing the Door’s Edge Opening Clearance inside the Frame

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!!

Top View Showing the Maximum Opening Angle of the Door in Frame

Was also able to test the maximum angle the doors could be opened.

3D Printed Hinge Pin Mount Parts and Lathe Screw Cutting Fixture

Part of the Hinge Pin design required turning (cutting) off some of the thread on a stainless fastener to create the hinge pin end.

Making a Hinge Pin from a Stainless Steel Screw on My Metal Lathe

Made a quick fixture to hold the stainless screws in my Metal Lathe’s jaws.

Brenda Picked Out Door Handles to Match the BBQ’s Curved Handle

Purchased the Door handles from LOWES to match the BBQ’s main handle.

3D Printed Hole Drilling Guides for Door Edges

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.

3D Printed Handle Screw Spacers to Adjust for Thin Sheet Metal

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.

SolidWorks Screen-Capture Showing Magnetic Door Catch Design

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.

3D-Printed Hinge Pin Mount Hidden Inside the Door

Mounted the hinge pin units after I finished drilling all the holes …

Stainless Screw Hinge Pin in BBQ Door

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.

3D Printed Spacers on Top and Bottom of Doors

Came up with an Upper & Lower spacer design that provided maximum coverage but also can not be viewed when door is opened and closed.

3D Printer Software Showing a Multi-Print of 16 Spacers

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.

Notes to Myself So I Would Not Drill Holes in the Wrong Location

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.

Using Paper Drawings as well as eDrawings Viewed on My iPad in Shop

Used the Miller Dynasty TIG welding machine in my workshop to make the door frames from 1.5″ x 0.125″ Stainless Steel angle …

Stainless Steel Door Frames Ready to be Mounted onto Concrete Blocks

Drilled lots of extra holes in the Stainless Steel door frames to allow for good anchor bolt/screw mounting locations on the concrete block.

Stainless Steel BBQ Door Frames

After the door frames were in place our neighbor finished the stonework …

View of the Finished Stainless Steel Doors Installed in BBQ Area

Neighbor very pleased with the results & I feel the doors look nice with stone.

Another View of the Neighbor’s New BBQ Area

In the photo below you can see one of the magnetic Ferritic Stainless catches.

Noticed I Forgot to Wipe off Finger Smudges Before Taking Photos

Below is one of the 3DP Hinge Pin Units with the Top Cover removed.

3D Printed Hinge Mount Combined with Stainless Steel Fasteners

As a bonus I got to be part of the first BBQ Cooking test!! 😜  Yum!!

Additional View of the Stainless Door Under the Patio Sink

As with many of my 3D Printing projects the CAD files are on GrabCAD.com
https://grabcad.com/library/3dp-bbq-door-hinges-1

Click on Image to View the CAD & .STL Files 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.
https://youtu.be/lQTs6abzWoc

SolidWorks Tutorial Video Showing How to Create a Mirror Image Part

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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3D Printed Band-Saw Fixture

My 3D-Printer is making me Lazy ( and I Love it )

Steel Channel Workshop Press

One can assume there are many ways to make angled steel washers, and probably even more places to buy several.

However, it was 10pm at night and I needed 32 Angled Washers in the morning and a way of making them.

As usual I looked to the 3D-Printer for a quick & easy solution.

Washers Angled on One Side and Flat on the Other

Luckily, years earlier, I didn’t listen to warnings from naysayers that said ABS filament 3D-Printers were just toys and could not make usable parts… because my workshop is full of ‘usable’ 3D printed parts.

Sometimes the simple items are the most helpful …

Post about: 3D-Printed MT-3 ABS Inserts

.STL files for 3D Printing items can be found on GrabCAD.com

3D-Printed MT-3 Shelf Inserts CAD Files

3D Printed Shelf Inserts for MT-3 Tooling

 

3D-Printed Knob to Open/Close Hydraulic Bottle Jack Valve

3D-Printed Open/Close Knob for Hydraulic Bottle Jack

 

3D Printed Hole Measurement Inserts

3D-Printed Threaded Measuring Inserts

 

3D Printed Drill Bit Holder

3D-Printed Drill Bit Holder for the Side of the Drill Press

 

Tabletop Drill Bit Stand

3D-Printed Tabletop Drill Bit Holder

 

Pipe Curve Scribe Guide

3D-Printed Pipe Curve Scribe Guide

 

3D-Printed Angle Washer Band-Saw Fixture

3D-Printed Band Saw Fixture for Cutting Angled Washers

 

Long story short – I designed a fixture to fit inside the clamp on my metal band-saw to cut angled washers.

3D Printing the two parts for the Band-saw Fixture

In the morning, my plan was to bolt together a project made from steel Channel with inner sides that have an approximate 9 degree angle.

Angle Washers on Channel Bolts

When cutting several holes in the sides of the channel I ended up with a few ready-made angled washer plugs and bored them out with the metal lathe to fit 3/8″ bolts … However, I needed a lot more angled washers.

Angled Slugs Create when Cutting 1″ holes with a Hole Saw

Looking at the Hole-Saw slugs gave me the idea of creating more angled washers.

Boring 3/8″ Holes in the 3/4″ Rod on Metal Lathe

I used 3/4″ mild steel rod and bored 3/8″ holes in each end of the rod …

3D Printed Angle Cutting Fixture and 3/4″ Metal Rod on Band Saw

The plan was to cut angled (9 degree) cuts on each end and then cut another set of straight cuts on each end to create washers …

Metal Rod in 3D Printed Band Saw Fixture

Was not sure if the 3D Printed ABS would hold the rod tight enough in the band saw’s clamp, so I put some vise-grip pliers on the other end of the rod to keep it from spinning …

Overhead View of the Band Saw Cutting the Angled Washer

The 3D Printed ABS split fixture more than held the rod tight enough …

Angled Washer after it was cut off Rod

Every cut creates an Angled Washer from the 3/4″ round stock …

Overhead View of the Band Saw Ready to make the Straight Cut

Outer edge starts out straight … then the first cut creates the 9 degree side of the angled washer … then rod flipped around …

Band Saw Cutting the Straight Cut Side of Washer

After both ends are cut angled, then the 3D Printed fixture is removed for the straight cuts.  Many Washers can be made switching back and forth from Straight to Angled Cuts

Switching back and forth from Straight to Angled Cuts

Process continued until I had enough angled washers to complete my project.

Another View of the Fixture holding the Rod after the Angled Cuts

It worked great!!

Once again ~ Sometimes the simple items are the most helpful.

Finished Angled Washers for Bolting items to the Channel

While I felt a bit lazy starting a 3D-Print and then going to bed to wake up the next morning with a finished part – I am quickly getting over the guilt. 😉

BTW ~ The reason the Workshop Press looks so unusual is because the parts store together as a Press, however, it can transform into 3 additional workshop tools … Sheet Metal bending Press Brake, a Pipe Bender, and a Hoist.

CHEERS!! . . . CHARLES MARLIN ( @MetalDesigner )

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3D Printed Hydraulic Jack Knob

20 Ton Hydraulic Jack with 3D Printed Knobs

This is another ‘simple’ 3DP ( 3D-Printed ) item to make life easier …

Hydraulic Jack 3D Printed (Open/Close) Knobs Project

I am designing a 36 inch long Sheet Metal bending Press Brake for DIY ‘Maker’ workshops and decided to use a Low-Profile Hydraulic Bottle Jack.

Compact Workbench 36 inch Wide Metal Bending Press Brake

Press Brakes are designed based on what material the user wishes to form …

Sheet Metal Thickness Dimensions Used to Figure Out Bending Tonnage

This new workshop sheet metal bending press brake will have an adjustable Vee-Die that will open from 1/2″ to 1.5″ across the V.

Vee-Die Examples Showing the Sheet Metal Bend Radius

A common method of calculating the ‘Air Bend’ Vee-Die distance is using the metal’s thickness multiplied 8 times, or 6 times for a tighter bend radius.

Link for more about Bending Sheet Metal with a Press Brake

If one knows the Vee-Die opening distance and the metal’s thickness then the bending tonnage can be calculated for different widths of metal.
( CINCINNATI  has a great Press Brake Load Calculator Webpage )

CINCINNATI Press Brake Load Calculator Website

First step was to decide on the maximum thickness of metal I will be bending, so I measured the 10 gauge mild steel I had in the shop. ( 0.136″ thick )

While I may bend thicker metal at lengths less than 36″, decided 10 gauge mild steel would be the max thickness bent at 36″ length in a 1.5″ V-Die.

CINCINNATI Press Brake Load Calculator said I would need 17 Tons to bend 36″ of 0.136″ thick mild steel in a 1.5″ V-Die.
http://www.e-ci.com/press-brake-tonnage-load-calculator/

Tonnage Calculations for bending a 36″ length of 14 Gauge (0.075″) Mild Steel

While I may bend 0.136″ thick metal from time to time, 16 gauge and 14 gauge will probably be the metal thicknesses I use the most for full 36″ bends.

BTW ~ CINCINNATI make Amazing metal bending Press Brakes and if I had room in my little shop I would buy one; however, since space is the limiting factor, I am going to make a small worktable size press brake.
( View CINCINNATI’s Press Brake Models )

Torin 20-Ton Stubby Bottle Jack purchased at LOWES

I found a low-profile Hydraulic Jack that fits the metal bending specs given by the Tonnage Calculator, so purchased the TORIN 20-Ton Stubby Bottle Jack online and picked it up later that day at my local LOWES store.

SolidWorks CAD model of the 20-Ton TORIN Low-Profile Bottle Jack

First thing I did was draw the Jack into SolidWorks with adjustable features …

SolidWorks Allows the Bottle Jacks Parts to be Adjustable

Knowing the Jack’s exact lifting dimensions will be helpful in future designs …

Since this Hydraulic Bottle Jack will be used with a metal bending press brake I may need to release the pressure quickly with one hand while supporting the metal with the other hand.

Hydraulic Jack Handle with the Replacement 3DP Open/Close Knobs

Using the handle’ notched end to Open & Close the hydraulic valve may be cumbersome at times; therefore, I needed to come up with a valve solution.

Concept for the Large Hydraulic Bottle Jack Knob

Decided to use SolidWorks to draw up Large & Small versions of knobs to Open and Close the jack’s hydraulic fluid value.

SolidWorks 3D Printed Concepts for a Large & Small Open/Close Knobs

3D-Printed the Knobs with a tight hand press-on fit and they worked great!!

3D-Printed the ‘Quick-Turn’ Knob for the Low-Profile Hydraulic Bottle Jack

I had black filament on the AFINIA 3D Printer so used it, but I will probably use an easier to see ‘brighter color’ in future versions of the Open/Close valve knobs.

Close-Up View of the Finished Large Knob for the Hydraulic Bottle Jack

Once again ~ Sometimes the simplest items are the most helpful 🙂

… CHEERS!!!

.   .   .   .

 

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3DP Hard-Hat Cooling Mount

Concept of the 3DP Mount Created with SolidWorks CAD Software

This is why I like SolidWorks CAD Software & 3D-Printing!!!  ( 3DP )

Wanted an unusual shaped mount, so decided to quickly draw & 3D-Print it.

Part 1-of-2 for the Mount that fits inside my Hard-Hat

When visiting job-sites in Las Vegas many require everyone to where a hard hat.

Last year I put some ice packets inside my hard hat to see if I could create a cooling effect to make it more comfortable when visiting job-sites during those hot 110 degree sunny Nevada days.

Ice Packets Being Tested inside a Hard-Hat Purchased from Home Depot

Usually I am just there to get measurements of something I need to design for the project; unfortunately, sometimes it means standing in the hot sun for hours.

The Cooling Test worked, so this year decided to make a permanent mount …

Screen-Capture Showing the AFINIA 3D-Printers Software

Designed a 2-part mount using SolidWorks and 3D-Printed the 2 parts …

Printing Part 2 of 2 of the Hard-Hat 3PD Mount

Nice thing about 3DP is one can draw very complex shapes without having to worry about draft angles which would have to be considered if injection molded.

Just-for-fun I added a mounting area for a temperature sensor inside …

Finished Part 2-of-2 for the Hardhat Mount

Bolted the mount to the hard-hat and everything still is located 3/4″ above my head allowing the cool air to slowly drift down over my head during hot days.

Later I will test different sealed cooling ice packets with a temperature sensor.

Finished 3D-Printed Mount inside Hardhat

Just another fun 3D-Printing (3DP) Project 🙂

… CHEERS!!!  

.    .    .    .

 

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Powder Coating Oven 3DP Parts

SolidWorks Rendering of the Powder Coating Oven Electronics Box

Earlier this year I started buying parts to make a Powder Coating Oven.

Controls inside the finished PCO Control Box prior to wiring

Controls inside the finished PCO Control Box prior to wiring

I will try to post images later to help others make their own PCO controller …

Controls Shown in PCO Control Box Prior to Wiring

The goal is to have a Portable Powder Coating Oven (PCO) with removable panels that can be configured into different shapes to allow for powder coating rectangular boxy shaped items as-well-as long thin items by heating the same volume of air with 2 heating elements. ( Total of 5170 watts )

Powder Coating Oven on Wheels allowing to to be moved anywhere in shop

Also a portable (Plug-in) PID Controller for the Powder Coating Oven … with the bonus that the PID Controller can also be used with my Beer Home Brewing Equipment and a future outdoor Meat Smoking Hut 🙂

Portable Powder Coating Oven PID Temperature Control Unit

For this Project my plan was to first draw in all the purchased parts and then start designing the rest of the items using SolidWorks CAD Software.

CLICK HERE to Learn more about Powder Coating

Powder Coating Oven Parts drawn into SolidWorks

Powder Coating Oven Parts drawn into SolidWorks

Attempted to order as many parts as possible off of AMAZON.com

Dayton 1TDV2 High Temperature Blower, 115 Volt, 129 CFM

Dayton 1TDV2 High Temperature Blower, 115 Volt, 129 CFM

As they arrived, I weighed the parts and drew them into SolidWorks …

Measuring a part's weight with a digital scale

Measuring a part’s weight with a digital scale

SolidWorks allows me to make the CAD part’s weight, and center of gravity, the same as the real-world part, so completed Assemblies are the correct weight.

The weight of the actual real-world part matches the SolidWorks CAD part

The weight of the actual real-world part matches the SolidWorks CAD part

SolidWorks also allows users to make Photo-Realistic renderings of the parts for presenting a visual of how real-life item will appear when finished.

SolidWorks Renderings of Parts for the Powder Coating Oven

SolidWorks Renderings of Parts for the Powder Coating Oven

I decided to 3D-Print many of the parts for the Oven’s Control Box …

3D-Printed Side Air Hole Vent Covers for Electronics Box

3D-Printed Side Air Hole Vent Covers for Electronics Box

First designed the Powder Coating Oven’s Electronics box with SolidWorks …

( Click on any image to see a larger view of the photo )

SolidWorks CAD Rendering showing the side Vent Covers

SolidWorks CAD Rendering showing the side Vent Covers

One of the benefits of using a 3D-Printer is designing any shape needed without worry of ‘draft angles’ which are required to make plastic injection parts.

For example, I wanted to be able to switch out different size/models of square shaped PID Controllers & Digital Timers.

Rounds Cutouts in Sheet Metal to Mount Square Controls

Rounds Cutouts in Sheet Metal to Mount Square Controls

So I designed and 3D-Printed a mounting setup which allows ‘square’ controls to go in a ’round’ hole easily drilled with a 2.5″ hole saw using a drill press.

Mounts to put a Square PID Control into a Round Hole

Mounts to put a Square PID Control into a Round Hole

Also designed and drew up some Cord Stop Clamps  ( .STL Files )

3DP Cord Stop Clamps to Keep Cords from Pulling Out of the Control Box

3DP Cord Stop Clamps to Keep Cords from Pulling Out of the Control Box

I like to show lots to dimensions in my drawings to prevent mistakes 🙂

Drawing of the Powder Coating Oven’s Front Control Panel

Tested the 3D-Printed parts, and the purchased parts, within the sheet metal cutouts prior to welding & painting the Electronics Box.

Testing 3D-Printed Parts in the Sheet Metal prior to painting

Testing 3D-Printed Parts in the Sheet Metal prior to painting

The electrical Terminal blocks I bought didn’t work, so I designed some …

Uploaded the 3Dp .STL files to GrabCAD ~ Link:  3Dp Terminal Blocks

SolidWorks Transparent View of the Electrical Connection Terminal Block

SolidWorks Transparent View of the Electrical Connection Terminal Block

Didn’t have 1/8″ thick Copper so found some Aluminum angle in scrap bin …

Drill and Tap Size Dimensions for creating the Terminal metal bar

Drill and Tap Size Dimensions for creating the Terminal metal bar

Drilled and Tapped the Aluminum and then cut it to the correct size …

Tapping Threads in the No.6-32 and No.10-24 Connection Holes

Tapping Threads in the No.6-32 and No.10-24 Connection Holes

3D-Printed one for White wires, and another for Black wires, and the ABS 3D-Printing material acts as an insulator for the 120V electrical connections.

Aluminum or Copper Flatbar sections press into a slot in the ABS Terminal Block

Aluminum or Copper Flatbar sections press into a slot in the ABS Terminal Block

The Cover keeps the screws from falling out even if they become loose …

Different Size Wire Terminal Ring Connections can be used on Terminal Bar

Different Size Wire Terminal Ring Connections can be used on Terminal Bar

I will probably switch out the Aluminum with Copper flatbar when I get some.

3D-Printed ABS material Cover protects the metal area of the connections

3D-Printed ABS material Cover protects the metal area of the connections

A specific feature I wanted for this (PCO) Powder Coating Oven was the ablity to know the cost of the electricity used while Powder Coating parts.

Amp Volt Watt Multi-Meter purchased from AMAZON.com

bayite Amp Volt Watt Multi-Meter purchased from AMAZON.com

The multi-meter comes with a ring which needs to go around the L2 electrical wire to know the Amps being used, so I designed and 3D-Printed a stand.

3D-Printed Amp Meter Ring Stand fits inside Electronics Box

3D-Printed Amp Meter Ring Stand fits inside Electronics Box

Below is a SolidWorks rendering showing the wiring and Amp Ring Stand.

SolidWorks Rendering showing how the L2 White wire fits into Ring Stand

SolidWorks Rendering showing how the L2 White wire fits into Ring Stand

The baylite Multi-Meter shows the Voltage, Current, Power, and Energy.

SolidWorks Rendering of the kWh Meter for Powder Coating Oven electrical cost

SolidWorks Rendering of the kWh Meter for Powder Coating Oven electrical cost

3D-Printed ABS material provides protection from other wiring in the box …

The finished 3D-Printed Amp Meter Ring Stand Mount for Powder Coating Oven

The finished 3D-Printed Amp Meter Ring Stand Mount for Powder Coating Oven

Tested each of the parts prior to mounting the in the electronics box ~ In the photo below I have the baylite meter setup to test 120v amperage; however, the meter is wired to 240V power in the Powder Coating Oven control box.

Testing the kWh Amp Meter unit prior to installing the the Electronics Box

Testing the kWh Amp Meter unit prior to installing the the Electronics Box

In future posts, after fully testing out the Powder Coating Oven, I will show the wiring in SolidWorks, which is easier to view than the real-life wiring because I will be able to hide, or make transparent, other items in the box to show specific wires going to specific items.

SolidWorks Transparent View of Powder Coating Oven Control's Wiring

SolidWorks Transparent View of Powder Coating Oven Control’s Wiring

I have already uploaded many of the CAD parts to GrabCAD.com

https://grabcad.com/charles.metaldesigner/projects

SolidWorks Rendering of Switches used in the Powder Coating Oven designs

SolidWorks Rendering of Switches used in the Powder Coating Oven designs

Tried to keep most of the items as Single part files; yet, still allow the parts to be adjustable, such as allowing switches to be viewed as ON or OFF.

The SolidWorks CAD switch can be set to show it as ON or OFF

The SolidWorks CAD switch can be set to show it as ON or OFF

Made the gap adjustable so the switch fits on other material thicknesses …

Gap of the Switch can be changes to match the thickness of metal

Gap of the Switch can be changes to match the thickness of metal

The LED Readout numbers can also be set for Tutorials & User Manuals …

The AUBER PID Controller keeps the the Oven's temperature consistent

The AUBER PID Controller keeps the the Oven’s temperature consistent

I try to use metal from my scrap metal bin to make equipment for my shop and sometimes the metal is heavier than I would normally use.

For example, the sheet metal for this PCO (Powder Coating Oven) Control box is 0.135″ thick and I would probably normally use 0.075″ thick sheet metal.

Welding the Powder Coating Oven Control Box Sides Together

Welding the Powder Coating Oven Control Box Sides Together

After drilling & cutting all the holes, I welded the Control box sides together …

The finished sheet metal PCO (Powder Coating Oven) Control Box

The finished sheet metal PCO (Powder Coating Oven) Control Box

Since this unit is for my shop I painted the PCO Control box Flat Black …

The PCO Control Box with Bolt-On Top & Back Plates

The PCO Control Box with Bolt-On Top & Back Plates

The Top & Back plates bolt-on to make the inner Controls easier to wire …

Painted the Powder Coating Oven (PCO) Control Box Flat Black

Painted the Powder Coating Oven (PCO) Control Box Flat Black

After the paint cured I started adding the controls & switches …

Installed the the Front LED Lights, Switches, Timer, and PID Controller

Installed the the Front LED Lights, Switches, Timer, and PID Controller

Noticed I was one ON/OFF switch short … They came in a Pack of 5 … *sigh*

Back on AMAZON to order more … For some reason I thought there was 6 🤔

All the Powder Coating Oven electronic parts fit in the box as designed

All the Powder Coating Oven electronic parts fit in the box as designed

After tests realized I didn’t need the Air Cooling fan but added one anyway.

Next Step is to add the 240V Outlets to each side of the PCO Control Box

Next Step is to add the 240V Outlets to each side of the PCO Control Box

Everything on the PCO is powered from outlets & extension cords, because this is a portable Powder Coating Unit that can be taken to different locations.

This Electronics box can also control a Meat Smoker & a Home Brewing system.
(  I wanted a multi-use Control Box for future projects ~ Whoo Hoo!!  )  😜

Front Blue LED lights-Up when the Blower Fan 120V outlet is switched ON.
Front Green LED Lights-Up when Oven Light 120V outlet is switched ON.

Fan Side View of the Powder Coating Oven's Control Box

Fan Side View of the Powder Coating Oven’s Control Box

The Amber Light on the front lets users know 240V power is plugged into the Control box … When dealing with 240 Volts – Safety, Safety, Safety!! ⚡

In addition,  the Amber LEDs on each side of the control box light-up when the Contactor Switch is providing 240V power to the 240V side outlets that are connected to the Powder Coating Oven’s Heating Elements.

Vent Side View of the Powder Coating Oven's Control Box

Vent Side View of the Powder Coating Oven’s Control Box

The White LED Lights-Up when 120V Power is plugged into the Control box.

I’m having ‘Laser Etched’ Metal Labels made up to explain Control functions.

View showing the 120V Outlets for the PCO's Blower Fan & Oven Light

View showing the 120V Outlets for the PCO’s Blower Fan & Oven Light

Additional Views of the Controls for the Powder Coating Oven …

Top-View Powder Coating Oven Control Box

Top-View Powder Coating Oven Control Box

Fan Side-View Powder Coating Oven Control Box

Fan Side-View Powder Coating Oven Control Box

 

Vent Side-View Powder Coating Oven Control Box

Vent Side-View Powder Coating Oven Control Box

 

There is a Switch to Turn ON/OFF the Air Cooling Side Fan

There is a Switch to Turn ON/OFF the Air Cooling Side Fan

 

3D-Printed Side Air Vents fit into 2.5" Holes cut with a Hole Saw

3D-Printed Side Air Vents fit into 2.5″ Holes cut with a Hole Saw

That’s All for Now 😜

Emergency Stop added to the front of the PCO Control Box

Emergency Stop added to the front of the PCO Control Box

I found the eStop button and added it to the PCO Control Box design …

SolidWorks Photo-Realistic CAD Rendering showing the Emergency Stop

SolidWorks Photo-Realistic CAD Rendering showing the Emergency Stop

Made a temporary stand/mount for the PCO Electronics Control Box …

I think PCO Stand/Mount sort of looks like a Robotic Kangaroo Rat

I think PCO Stand/Mount sort of looks like a Robotic Kangaroo Rat

Already has the nickname of ‘Roo-Rat’  😜

Click on image to see a larger view of PCO Controller on Stand/Mount

Click on image to see a larger view of PCO Controller on Stand/Mount

I uploaded my SolidWorks ‘Working CAD Files’ to GrabCAD for anyone that would like to see how I tested the wiring.

The wiring in the model is not complete, but it will show how I wired the Auber PID Temperature Control, as-well-as the Inkbird Timer Control and the Digital Amp/Volt Meter.

GrabCAD Link: https://grabcad.com/library/powder-coating-oven-wiring-1

Prototype Wiring CAD Model Files Uploaded to GrabCAD.com

The Powder Coating Over Controls I used were:

Auber SYL-2342  PID Temperature Control
( SYL-2342 version is for Contactors not SSRs )

INKBIRD IDT-E2RH  Timer

Eaton C25BNF240A  Compact Definite Purpose Contactor

Bayite AC 80-260V LCD  Watt Multimeter Ammeter Voltmeter

AC Infinity AXIAL 8038   Muffin Cooling Fan, 115V AC

Erb44t10010  2,585 watt Heating Elements ( 2 )

If you have any wiring/control Questions send me a comment  🙂

… CHEERS!!!

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Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, HOMEBREWING, PROJECTS, SolidWorks CAD Rendering, WORKSHOP

3D-Printed Bench Leg Extensions

Turtlebutt Getting Up-Close and Personal with the Camera

Turtlebutt Getting Up-Close & Personal with the Digital Camera

Turtlebutt ( The Amazing Adopted Desert Tortoise ) is part of a Nevada adoption program whereby protected Desert Tortoises that are injured or born in captivity cannot be released back into the wild.

Turtlebutt Feeding Out in the Grassy Area in the Back Yard

Turtlebutt Feeding Out in the Grassy Area in the Back Yard

By law Desert Tortoises may not be removed from the State of Nevada; therefore, homeowners will volunteer to let a Desert Tortoise live in their enclosed backyard area and make sure they are fed and have a place to hibernate underground during the cooler Nevada months.

If a family is moving out of the State of Nevada, they or the adoption program, must find a new home in Nevada for the protected Desert Tortoise to live & hibernate … and that is how we came to live with Turtlebutt the Tortoise.

Completed Patio Bench with Leg Extensions and Threaded Levelers

Completed Patio Bench with Leg Extensions and Threaded Levelers

Turtlebutt is very friendly and will come over to visit if you are outside, but he is a bit of a bulldozer when moving from one point to another, and if something is in his way he will go over it, or under it, or drag it with him.

Rub Marks from Turtlebutt's Shell When He Goes Under Bench

Rub Marks from Turtlebutt’s Shell When He Goes Under Bench

As Turtlebutt has grown over the years, he has started dragging the Patio Bench with him more and more, to the point it seems like he enjoys it … But we like to keep the bench in one place, so decided to raise the bench a little so he doesn’t drag it with him as he crosses the patio.

3D-Printed Leg Extension with Threaded Bench Leveling Foot

3D-Printed Leg Extension with Threaded Bench Leveling Foot

Later this year when it is not 110F. in the workshop, I will cut and TIG weld the Aluminum side supports at a higher position and possibly arc the supports a bit to account for Turtlebutt’s growth.

As a quick fix this summer decided to 3D-Print some Bench Leg Extensions …

SolidWorks CAD Software Transparent View Showing Press-in Nuts & Bolts

SolidWorks CAD Software Transparent View Showing Press-in Nuts & Bolts

I drilled holes & tapped threads for one 8mm machine screw and four small #6 screws into the bottom of each bench leg … Then used the SolidWorks design shown above to press-in 1/2″ nuts to mount the Threaded Foot Pad Leveler bolts into the 3D-Printed Leg Extensions.

It Would Take 9 Hours to 3D-Print all 4 Parts at Once

It Would Take 9 Hours to 3D-Print all 4 Parts at Once

While I could have 3D-Printed all 4 Leg Extensions at once, the printing process would have taken 9 hours and I wanted to be able to test one of the Leg Extenders prior to printing the rest.

It would not have been an issue to do a 9 hours print, because after you press the START Button, you can go to bed or walk away and do something else and come back 9 hours later and the parts will be done … Feels like getting to work on two projects at once when items are 3D-Printing.

Leg Extensions Printed on the AFINIA H-480 3D Printer

Leg Extensions Printed on the AFINIA H-480 3D Printer

In the Photo above, I set the finished 3D-Printed Leg Extenders on the Printing Platform to show the size of the items in relation to the 3D-Printer.

( Click on any photograph to see a Larger View of the image )

Larger Front Leg Extender Shown in the AFINIA 3D-Printing Software

Larger Front Leg Extender Shown in the AFINIA 3D-Printing Software

Since I wanted to test the size and fit-up of just one of the Leg Extenders first, I opened up the Large Front Leg Extender .STL file and 3D-Printed it using AFINIA‘s  ‘ Natural ‘ Color PLA 3D-Printing Filament

( Would have printed them black but did not have enough black filament )

SolidWorks CAD Software View Showing the 4.5 Degree Base Angle

SolidWorks CAD Software View Showing the 4.5 Degree Base Angle

Due to the shape of the original bench design, the Back Leg Extenders needed to have a 4.5 degree base angle to match the angled Aluminum legs.

Smaller Angled Back Leg Extender Shown in AFINIA's 3D-Printing Software

Smaller Angled Back Leg Extender Shown in AFINIA’s 3D-Printing Software

No worries, the 3D-Printer can print a RAFT of support material to build up on the platform to print items that don’t touch the printing platform base.

RAFT Material is Removed from Parts after being 3D-Printed

RAFT Material is Removed from Parts after being 3D-Printed

Once the parts are finished 3D-Printing the extra support material can easily be pulled off revealing the 3D-Printed parts …

Yellow Lines Show the Location of the Extra PLA Filament RAFT Support Material

Yellow Lines Show the Location of the Extra PLA Filament RAFT Support Material

Had just enough of the AFINIA Premium PLA Black Filament on the Spool to print the Foot Pads that press onto the Hex Ends of the Zinc coated Steel Bolts.

Three Foot Pads being Printed at Once after 1st one was Test Printed

Three Foot Pads being Printed at Once after 1st one was Test Printed

As before, I printed just one Foot Pad to make sure it would press on tight, and then printed the final 3 Foot Pads together on the 3D-Printing platform.

Close-Up View of the 3D-Printed Leg Extension on the Bench Leg

Close-Up View of the 3D-Printed Leg Extension on the Bench Leg

Once the Patio Bench Leg Extension parts finished 3D-printing, I then screwed them onto the bottom of the legs using the tapped threaded holes …

Close-Up View of the Threaded Leveler Bolt Screwed into Extension

Close-Up View of the Threaded Leveler Bolt Screwed into Extension

Next ( prior to painting ) pressed the black Foot Pads onto the bolt heads to act as threaded Leg Levelers … They worked as expected stabilizing the bench.

Bench Turned Upside-down Showing the Leg Extension & Leveler

Bench Turned Upside-down Showing the Leg Extension & Leveler

Painted the Zinc coated bolts black so they would blend into the black bench …

Threaded Foot Pad Leveler prior to being painted black

Threaded Foot Pad Leveler prior to being painted black

After testing all the parts, I decided to test the threaded levelers on the Patio.

Leg Extensions Mounted on Bench ready to be Painted Black

Leg Extensions Mounted on Bench ready to be Painted Black

Before painting the Leg Extenders, the White filament color made the bench look like it was doing a Michael Jackson or Elvis ( white socks ) impression.

Testing to Make Sure Bench Threaded Levelers Work Correctly on Patio

Testing to Make Sure Bench Threaded Levelers Work Correctly on Patio

The bench was rock solid stable on the Threaded Leveling Foot Pads so I painted all items black and once dry put the bench back on the patio.

Finished Patio Bench Raised to Allow Turtlebutt Easily Walk Under

Finished Patio Bench Raised to Allow Turtlebutt Easily Walk Under

The next time Turtlebutt is under the Patio Bench I will get a Photo of him.

Those are Actually Berries *grin* ... Turtlebutt Does NOT Ever Bite People

Those are Actually Berries *grin* … Turtlebutt Does NOT Ever Bite People

… CHEERS!!

UPDATE:

Turtlebutt went under the bench today with lots of clearance!!

Turtlebutt Walking Under the Raised Patio Bench

Turtlebutt Walking Under the Raised Patio Bench

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3D-Printed iPhone Tripod Mount

3D-Printed an iPhone Mount for the 3D-Printed Tripod Mount

3D-Printed an iPhone Mount for the 3D-Printed Tripod Mount

My iPhone seems to take video as good as any other camera, so decided to make a 3D-Printed mount for it to fit on the 3D-Printed Tripod Mount …

SolidWorks CAD Model Concept for the iPhone Mount

SolidWorks CAD Model Concept for the iPhone Mount

Wanted a mount that would connect over the existing cover and would also be easy to quickly slide the iPhone in & out of …

Designed the Concept using SolidWorks CAD Software.

SolidWorks Parts for the iPhone Mount Prepared for 3D-Printing

SolidWorks Parts for the iPhone Mount Prepared for 3D-Printing

After drawing the individual parts, lined them up to prepare for 3D-Printing.

Top-View of the iPhone Mount Parts in AFINIA's 3D-Printing Software

Top-View of the iPhone Mount Parts in AFINIA’s 3D-Printing Software

I use an AFINIA H-480 3D-Printer and it gives a preview of the print platform.

AFINIA's 3D-Printing Software shows a Preview of the Printing Area

AFINIA’s 3D-Printing Software shows a Preview of the Printing Area

Pressed start and 2 hours and 22 minutes later had the iPhone mount parts.

3D-Printing Software Predicts the Filament needed & Time to Print

3D-Printing Software Predicts the Filament needed & Time to Print

Moved the 3D-Printer to a better area on the new inside Workshop Table.

3D-Printer moved to it's new location on the inside office Workshop Table

3D-Printer moved to it’s new location on the inside office Workshop Table

The 3D-Printed mount allows photographs & videos to be taken from either side of the iPhone, and the strap can be attached to the Tripod for ‘drop’ safety.

Photo & Videos can be Taken from Either Side of the iPhone on Mount

Photo & Videos can be Taken from Either Side of the iPhone on Mount

The mount is designed for the Ringke MAX  iPhone 6 case.

Ringke Max iPhone 6 Shock Absorbing Case with Neck Strap

Ringke Max iPhone 6 Shock Absorbing Case with Neck Strap

3D-Printing .STL Files can be found on GrabCAD  🙂

… CHEERS!!!

.   .   .   .

 

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Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, PROJECTS, SolidWorks CAD Rendering, WORKSHOP