Making Bialaddin bowlfire guards

Got one step closer to being able to start making bowl fire guards. I had some scrap ply and time so I knocked up this jig....







Going to source some 2.5 and 3.5 mm wire soon and some silver solder. Stainless wire would be too costly, I think galvanised fencing wire would be OK and would not be a problem at these temperatures but thought I would enquire here?

Steve

 

Oh and how would I make these images bigger? I had to re-size them down to 190 in Windows Live photos before they would upload onto this site.

Steve

 

Reduce the resolution on your camera probably - I have mine set to take images 640 x 480 pixels which is forum-preferred size.

When you've got them ready for posting (cropped and such), save them on your computer and reduce the save quality (i.e. compression) to around 25% and set the dpi to no more than 72dpi - a computer monitor cannot display any higher than that. Hope that helps...

 

Ah, I had the camera set to 4608X3456!!

Cheers David,

Steve

 

Great work! Show us the results once you have the first finished

 

Sorry for being a dunce but...I have changed the camera setting but can't seem to find where to do the compressing and to set the dpi?

Steve.

Edit: Think I'm gradually working out this pic sizing thing!

 

This is IrfanView and I've cheated a little by showing the two steps on one image:-



But whatever image manipulation software you're using will have the same or similar dialogue boxes...

 

Here is my first attempt at making a guard...
First making the large circle...





Brazed...



Now the small circle formed round a gas bottle!...



Making the grooves for the spokes...

 

The first two cross bars go on...



Then I cut all the spokes and numbered them...



I then brazed them all together, first the large circle then the smaller...



Here is the finished guard...







With one coat of paint...



Hope you likey,

Steve

 

Fine fettling!

 

Cheers Jeff

I just totted up the materials cost...

Metal-£1
Silver braze rods-£3.25
Paint-£0.50

Total-£4.75

Will have to look for cheaper brazing rods, got those at B&Q?

It took me around 3 hours to make but this was the first time and I was sorting out bugs as I went! Reckon I could get the time down by half or even 2 thirds?


Steve.

 

Great job Steve !

Do me a favour though aye ? Be careful with Galvo ! Do a google search on zinc oxide poisoning ! And satisfy yourself that your doing your great work in an appropriate environment

Not being a pooper, just a little concerned buddy, gotta stay safe ain't we

 

Ta for the concern. I did know about the zinc fever so I did the brazing outside with the wind away from me. Also had a paper mask on for all the good it did? I hope this is enough protection? I may have to get a proper mask if being outside isn't enough?

Steve.

 

Top man Steve

Hope you get plenty of orders and glad your not pi££ed with me for my penneth worth

 

I know how difficult making these guards can be so don't sell yourself short , they look the buisness 8) Well done 8)

As Ray says be careful of the galvy coating , nasty stuff when welding or brazing so keep safe

Stu

PS stainless would be good 8)

 

Cheers guys.

Longiliy, not at all i'm glad of any advice

Stu, actually it went better than I thought! Yes it took a while and the next will probably need a bit more fettling to get them to where I want them but overall pretty good!

Stainless would be good and I did buy some in with the intention of making them out of it but the cost would have been prohibitive? At just over £20 for the rods on ebay with the postage!! Must be a cheaper source?

I'm thinking at the temperature these guards operate at there will be no danger of zinc fumes being produced in use? Plus the paint would protect the zinc somewhat?


Steve

 

Hi Steve

Try a local welding supplier or workshop & get some stainless tig welding rods & they're good to work with 8)

Stu

 

Steve,

You've done a marvellous job! I am sure you'll get lots of orders, esp. For the stainless model

 

I have seen some stainless tig rods on ebay and reckon that it would come out at about £5 per guard? Plus the silver braze and gas around £8 total?

If I start making these would stainless be the way to go? And would £20 plus postage be reasonable?

If any one is interested let me know?

Steve

 

Stainless is definately the way to go

 

A few of us had some made up in stainless steel by a member over at CCS. IIRC, the cost was £25 plus p+p. I thought that wasn't unreasonable at all, particularly considering the research and development casts for the jig and so on. Good job, too

What are you proposing to do for the two suspension clips at the top?

 

Cheers David

Forgot all about the clips Will knock summat up tomorrow!

Steve

 

Agreed

Stainless Steel replica guard for £20? Sounds reasonable to me. I'll have one!

Sid.

 

Sid, Ok I will pencil you in.

Have ordered some stainless so when it arrives will make one up then post a pic and if you want it will post, then if you could tell me what you think?

Ta Steve

 

Hi Steve,

Cracking good result; well done mate . Have you also sorted the securing clips necessary for the guard? If you do go for a production run I would prefer stainless and I think that your proposed price is very fair, considering the work involved. I will be in the line, so let me know when you are taking orders.

Steve.

Steve.

 

Hi Steve, have not done the clips yet. Had a monumental garage clear out today and also made another jig to hold the large ring in place for brazing. Did not realize how springy 3.2mm stainless is!!

Will let you know when I have some made up.

Steve.

 

Steve, as a mere woman who knows nothing about anything technical could you please pencil me in for one too?

 

Yep will do

These are going to be made in my spare time so there will be a small wait.

Also I'm in negotiation with an ebayer for some 3.2mm rods in 1000mm lengths for the large ring so this may be a while? They only do them in 5kg batches i.e lots and lots of rods for £70 and I only need a few for now!

Steve.

 

Made up a few clips today...




.
Also the 3.2mm rods turned up an hour ago, still waiting for the 2.5mm rods though.

Steve

 

I now have the rods but the silver solder has not arrived yet.

Working with stainless is much harder than the fencing wire, loads of spring to it, but I'm getting there.

The hardest bit to make is the small ring but I managed a couple of good ones after getting the technique right.

Steve.