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Do It Yourself With Aluminum. 125 Projects For The Home Craftsman | by Author: G. W. Birdsall



This book presents a wealth of shop kinks and short cuts to help the home craftsman get the most out of that fascinating new material, Do-It-Yourself Aluminum. Here are recommended methods for fabricating this metal with the ordinary woodworking tools found in any home workshop.

TitleDo It Yourself With Aluminum. 125 Projects For The Home Craftsman
AuthorG. W. Birdsall
PublisherMcGraw-Hill Book Company, Inc
Year1955
Copyright1955, McGraw-Hill Book Company, Inc
AmazonDo It Yourself With Aluminum
-Preface
This book presents a wealth of shop kinks and short cuts to help the home craftsman get the most out of that fascinating new material, Do-It-Yourself Aluminum.
-Chapter 1. Do-It-Yourself Aluminum. The Material
Like other metals, aluminum has many advantages over wood in that it does not warp, rot, mildew, split, splinter, or crack. No knots detract from its perfectly ...
-Chapter 2. Shop Kinks And Short Cuts
Recommended methods for fabricating Do-It-Yourself Aluminum with ordinary woodworking tools in the home workshop. Marking Be sure the surface is free from oil ...
-Shop Kinks And Short Cuts. Continued
To cut off lengths of tubing, rod, bar, or special shapes on a bench saw, clamp a 1 x 4 wood board to the miter gauge of the saw so that it supports the work ...
-Chapter 3. Bending, Forming, Shaping
Turning Sheet Edges For making flanges (a 90 bend ) or folds (180 bend), slot a block of wood and hold it in a vise while bending the sheet with the edge in ...
-Bending, Forming, Shaping. Continued
Spiraled Bar Both 1/8 x 3/4 and 1/4 x 1 aluminum bar make attractive ornamental spirals. Simply clamp one end in a bench vise, and twist the other end with a ...
-Chapter 4. Joints And Fastening Methods
General This chapter presents methods for joining the various pieces of Do-It-Yourself Aluminum to each other and to other materials. It shows many types of ...
-Rod Connections
Machine Screws Figure 4-12 shows rod A T-connected to another rod B. Drill A to pass 10-24 machine screw. Drill and tap B to take 10-24 aluminum screw. This ...
-Bar Connections
End-To-End Bar Joints .... Lap Type Lap joints are suitable for joining 1/4 x 1 bar stock. In Fig. 4-26, the bar is halved in thickness. In Fig. 4-27, the bar ...
-Angle Connections
Cobner Joints In Angles Figures 4-33 and 4-34 show easily made corner joints in 1/8 x 3/4 x 34 angle. Either bevel ends or overlap ends. Saw off a length of 34 ...
-Angle Connections. Continued
Angle-To-Ancle Joint The best way to connect one angle to another in either a T-joint or an X-joint is to bolt or rivet the two adjacent legs as in Fig. 446.
-Tube Connections
Mounting Legs made of aluminum tube is involved in such projects as the dining-room table of Fig. 8-1 and the sawhorse of Fig. 6-1. The only unusual operation ...
-Tube Connections. Part 2
End-To-End Joints To connect two tubes of the same size permanently, join with an internal sleeve as detailed above and secure to both tubes with self-tapping ...
-Tube Connections. Part 3
Hose-To-Tube Coupling Figure 4-81 shows how to drive a standard hose connection into a piece of 3/4 tube, using a wood dowel rod to prevent damage to the ...
-Chapter 5. Surface Finishing
Natural Finish All aluminum is covered with a film of aluminum oxide which protects the underlying metal so that aluminum needs no paint or other coating to ...
-Ornamental Designs
Reproducing A Design Make a template of heavy paper, as in Fig. 5-9, and use this to shield the portions of the aluminum surface which you wish to remain ...
-Chapter 6. Projects For The Workshop
Sawhorse (Fig. 6-1) requires four 2' lengths of 11/4 aluminum tube for the legs. The top piece is a 3' length of 2 x 4. Crosspieces are 10 lengths of 2 x 4 ...
-Chapter 7. Projects For The Kitchen
Shopping Cart (Fig. 7-1) is 12 across the front and 12 on a side so a single sheet of perforated aluminum makes the front and both sides. The cart proper is ...
-Projects For The Kitchen. Continued
Serving Cart (Fig. 7-12) has plywood serving top 17 x 21 . Box of plywood is 12 high at front end, 15 high at back end, 26 long front to back, 18 wide, outside ...
-Chapter 8. Projects For The Dining Room
Dining-Room Table (Conference Table) With the color scheme suggested, the table shown in Fig. 8-1 presents an exceptionally bright, highly modern appearance.
-Projects For The Dining Room. Continued
Recommended Sequence Of Finishing Operations Sand the Nov-A-Ply table surface perfectly smooth and level. Seal by brushing on two thin coats of transparent ...
-Chapter 9. Projects For The Bedroom
Rods for Clothes Closet (Fig. 9-1) are made from 11/4 tube cut to exact distance from wall to wall minus 1/4 for clearance. Two 1 thick wood blocks, 4 square ...
-Chapter 10. Projects For The Study Den
Designer's Desk (Fig. 10-1) is a high-style item with several novel features. Desk top itself is 3/4 plywood cut to 30 x 60 . Six pieces of 1/8 x 3/4 x 3/4 ...
-Projects For The Study Den. Part 2
Study Desk (Fig. 10-5) employs a cull door which is cut to 24 x 48 and open edges closed with wood to match the solid edges. Or a 3/4 thick piece of plywood ...
-Projects For The Study Den. Part 3
Magazine Rack (Fig. 10-10) utilizes two pieces of 3/8 rod each 42 long for the frame and a single piece of embossed sheet 12 x 30 for the container. Start ...
-Chapter 11. Projects For The Living Room
Serving Wagon (Fig. 11-1) has top 20 wide, 26 long, plus ice box. Shelf under top is also 20 wide, 38 long. Bottom shelf is 20 wide, 40 long. Make the three ...
-Projects For The Living Room. Part 2
Cocktail Table with Magazine Rack (Fig. 11-4) has top surface 20 wide, 38 long, trimmed with 1/4 x 1 bar on edge. One piece of bar goes down the front side and ...
-Projects For The Living Room. Part 3
Round Tables The design shown in Fig. 11-11 is adaptable to a wide variety of sizes. After rutting out a top of 94 plywood, smooth the edge with a rasp and ...
-Projects For The Living Room. Part 4
Prepare top-shelf ends (item 3) by drilling a 1 diameter hole 1 from rear end in both pieces; then drill a 1 hole 1094 from center of this hole for front leg.
-Projects For The Living Room. Part 5
Now install the sliding doors, and attach the two vertical frame strips (1/8 x 3/4 bar) 18 from each end in the top cabinet. The two silver drawers below the ...
-Chapter 12. Projects For The Porch, Terrace, Lawn
Lawn Cane Tray (Fig. 12-1) is handy outside anywhere as it is held in position by pushing the sharpened point into the ground. The 3/8 rod is in two sections ...
-Projects For The Porch, Terrace, Lawn. Part 2
Picnic Table, Benches (Fig. 12-8) use 1/8 x 3/4 x 3/4 angle for frame with 3/8 rod for bracing. Table and bench surfaces are redwood 2 x 4's or 3/4 plywood.
-Projects For The Porch, Terrace, Lawn. Part 3
Cocktail Table (Fig. 12-12) features two large shelves for magazines and a two-level design that adds an air of distinction. This large table should be used ...
-Projects For The Porch, Terrace, Lawn. Part 4
Terrace Light (Fig. 12-17) is a modern design with simple lines. A 1/16 x 1 x 1 angle 12 long is riveted to a x 1 bar which is formed to hold the cone ...
-Projects For The Porch, Terrace, Lawn. Part 5
A 3/8 hole drilled through this connection permits passage of a 2 1 length of 3/8 rod which extends through the main frame to support two small wheels, ...
-Chapter 13. Projects For Home Improvement
Screen-storage Rack (Fig. 13-1) stores screens or storm windows overhead in garage or basement. Vertical supports are 2 x 4's nailed to ceiling joists in ...
-Projects For Home Improvement. Part 2
Screen Porch Or Breezeway Any porch can easily be screened in completely with Do-It-Yourself screen sections. Divide porch or breezeway sides into panels 24 or ...
-Projects For Home Improvement. Part 3
Stepladder (Fig. 13-10) offers amazing lightness yet ample strength when made of 1/8 x 3/4 x 3/4 angle, tube, and 1/8 x 3/4 bar as marked on the drawing.
-Chapter 14. Projects For The Children
Child's Table and Chair Set (Fig. 14-1) will greatly enhance any child's room and provide an excellent work and play center. For the table, cut out and screw ...
-Projects For The Children. Continued
Play Tent (Fig. 14-5) will give the youngsters no end of fun. Dimensions suggested, of course, may be enlarged easily if desired to make room for beds. Use 11/ ...
-Chapter 15. Cost Estimating
Often when working out a design or considering a project, you may wish to know the cost of the material required for it. The following table presents typical ...









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