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Restoring a Herman Miller Eames chair. . Custom Delrin feet. More pictures after completion.

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So, apparently I’m in the craft of making hairpin legs for the people I care about… I may actually start producing them as a product, though there are far too many competitors out there.

My wife asked me to make four for our kids’ art table that she wanted to make as a Christmas present ti them. I made 16 instead. .. Four of them (for the kids’ art table) were made to be 20” high, painted matte turquoise on the top 5”, and clear lacquered the rest of the way down. The rest went to a few other projects for my older sister and I…

These seem to be superior to most of the commercially available units as the are made with 7/16” cold rolled steel (not 3/8” hot rolled steel), the top plates are 3/16” (not 1/8”  or 10ga.), and the legs are fillet welded at the base of the top plates AND plug welded on the top of the top plates. I made a couple of jigs that made the replication super consistent, and I can make them virtually any height.  The top plates were very easy to make, because I just plasma cut them all… I’m considering powder coating a few sets too…

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A credenza That I made for my wife for her birthday. Oh, and six shelves… If you look closely, the breaks between the shelves are staggered. This took more layout and attention to detail than you would believe! All of the shelf brackets are welded to the shelves, and had to be dead-on to hit studs. I chose to put the shelf brackets on top to act as bookends, and when books are actually in place, the shelf brackets disappear. This causes the viewer to see the lateral shelves as floating pieces of 10 gauge (1/8”) platforms with no obvious retainers.

The credenza is 3/4” square tubing, skinned with 14 gauge HRS, and the doors are 1/4” birch veneer plywood. I had to make custom bypass door tracks from scratch to accommodate my design. I plasma cut the counter top out of 10 gauge HRS, and finished it with beeswax. If you look close, you can see the cord grommet that I incorporated.

Hope you like it!

PS… I know my photos suck, but you get the idea!

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The chair, next to the jigs…

The chair, next to the jigs…

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Here’s the jig for the top of the chair. It’s all 1/4”  A36 plate. Still need to make the bending dies, and a stand for the whole thing… The chair only uses two pieces of steel rod, hence the two part jig.

Here’s the jig for the top of the chair. It’s all 1/4” A36 plate. Still need to make the bending dies, and a stand for the whole thing… The chair only uses two pieces of steel rod, hence the two part jig.

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So, I’m in the smack-middle of building a jig to bend steel rod into chairs. It’s a two part jig, the base (shown), and the top. Look close for the awesome joinery at the corners… Many more posts to come on this project!

So, I’m in the smack-middle of building a jig to bend steel rod into chairs. It’s a two part jig, the base (shown), and the top. Look close for the awesome joinery at the corners… Many more posts to come on this project!

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One more picture to see both walls.

One more picture to see both walls.

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More shots as requested. Seat is Masonite with 12 fixing rivets, and 6 holes (holes represent six slices of pizza as these will be going into a pizza place). The chair is made of two pieces of 7/16” CRS rod, two pieces of 16ga. steel, one piece of Masonite, and 12 rivets. It has 12 1.5” radii and 3 bows (for the seat and back).

GIVE ME FEEDBACK PLEASE!

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Prototype finished….

Prototype finished….

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So far the prototype has given me a run for my money, but it is coming along… As it stands, It’s two pieces of steel (1 20ft. Stick of 7/16” CRS), and twelve 1.5” radius bends. There will be more to follow…

So far the prototype has given me a run for my money, but it is coming along… As it stands, It’s two pieces of steel (1 20ft. Stick of 7/16” CRS), and twelve 1.5” radius bends. There will be more to follow…

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Five minute study in wire frame chair design. Not at all what the finished product will look like, just seeing what would happen when I started bending bailing wire. I am designing a chair with as few components as possible that will cost very little to produce… LONG way to go yet…

Five minute study in wire frame chair design. Not at all what the finished product will look like, just seeing what would happen when I started bending bailing wire. I am designing a chair with as few components as possible that will cost very little to produce… LONG way to go yet…

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Keyboard, etc. drawer. Did I mention this computer cabinet was almost entirely made of recycled and free materials? The only parts I purchased were the casters and blue paint…. the frame was made from a porch swing that my neighbour through away, the melamine came from a treadmill, the acrylic widow was out of a drugstore display, and the drawer guides were from an old sink display from my last job. Almost forgot, the cooling fan for the computer enclosure was something I found 8 years ago in the trash.

Keyboard, etc. drawer. Did I mention this computer cabinet was almost entirely made of recycled and free materials? The only parts I purchased were the casters and blue paint…. the frame was made from a porch swing that my neighbour through away, the melamine came from a treadmill, the acrylic widow was out of a drugstore display, and the drawer guides were from an old sink display from my last job. Almost forgot, the cooling fan for the computer enclosure was something I found 8 years ago in the trash.

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New computer cabinet for the PlasmaCAM. Just something quick and dirty to keep the nasties out of the computer. It’s self cooling with filtered air supplied from a 5” fan, a 4 square foot drawer (to stow keyboard, mouse, software, and consumables), and four swivel casters that all lock to keep it in place. I had to paint it, so I just matched it to the table… Next up, mobile base for the table, sheet material handler, and massive downdraft exhaust system.

New computer cabinet for the PlasmaCAM. Just something quick and dirty to keep the nasties out of the computer. It’s self cooling with filtered air supplied from a 5” fan, a 4 square foot drawer (to stow keyboard, mouse, software, and consumables), and four swivel casters that all lock to keep it in place. I had to paint it, so I just matched it to the table… Next up, mobile base for the table, sheet material handler, and massive downdraft exhaust system.

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dustdb:

Check out some updated photos of the Tucson Mountain House on our website, photos by Jeff Goldberg / ESTO

Looks amazing! I am super honored to have been able to work with these creative geniuses on this. More Pictures please!

dustdb:

Check out some updated photos of the Tucson Mountain House on our website, photos by Jeff Goldberg / ESTO

Looks amazing! I am super honored to have been able to work with these creative geniuses on this. More Pictures please!

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New electrical pulled to the west side of my shop.  3 220v outlets, 4 duplex receptacles (8 110v outlets). Hopefully this will cover that side of the shop until I can just get a new shop. Next up, big downdraft exhaust system for the PlasmaCAM, and a computer cabinet to protect the control computer.

New electrical pulled to the west side of my shop. 3 220v outlets, 4 duplex receptacles (8 110v outlets). Hopefully this will cover that side of the shop until I can just get a new shop. Next up, big downdraft exhaust system for the PlasmaCAM, and a computer cabinet to protect the control computer.