Coat Rack From Railroad Spikes

Decided we needed a coat rack to hang our coats on chilly days when taking off and returning from a Jeep ride.  I had some 2" flat stock, found some railroad spikes from a kid on Craigslist and brought out the trusty FC-90 flux core welder.

Evaporusted the spikes, cut them down to 5" and welded them onto the bar stock.  Drilled the bar stock at 32" on center.  Found a couple of 1/2" spacers so the coat rack would "float" off the wall and screwed it into the studs.

I painted it with that Rustoleum hammer finish spray paint (gray), let it dry, then used some Rustoleum satin black oil based paint in a can and brushed on a solid coat of black, then immediately wiped it off.  What was left made it look old.  

I think it came out nice... what do you think?

Welders • Welding Info • Welding links

These are the welding products that I've purchased.  The Amico stick welder is definitely harder to master.  The Century DC flux core welder is a dream to use so I've used it for almost everything I've done to the CJ (non-structural).

 

Amico DC-160A Stick Welder

Century K3493 FC-90 • 90 Amp DC Flux Core Wire Feed Welder

 Upgraded the FC-90 ground clamp to the Berger 300 amp copper


Antra AH6-260-0000 Auto Darkening Welding Helmet


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License Plate Bracket Fix

The license plate frame has slid to the right on a couple of occasions allowing the tailgate to rub against it.  Decided to weld a washer to the license plate bracket to prevent it.  Also positioned the washer 1/4" beyond the previous left most position to add clearance between the license plate frame and the tailgate.

Third Hand - Welding

Welded up a third hand using a block of steel I found and some 1/2" rod.  Decided to use a rolling rod instead of two legs on the back side so it could span the slots in my table.  Ground a flat blade "screwdriver" tip to hold parts in place.

Getting better with the welder (inset).

Welding Torch Holder

Decided to make a torch holder for the welding table.  Design requirement was for it to accommodate both the stick holder and the flux core wire holder.

 Cut some lengths of 1/8" x 1" bar stock.  Purchased the 95 lb. magnet from Harbor Freight. Pre-weld setup using vise-grip and magnets.  You can see my torch holder draped over the vise-grip... which illustrates problem.

Cut a 3" length of PVC conduit and cut out a section that fits the stick holder.  The width of the cut fits on either side of the boss on the stick holder.  This will prevent the stick holder from rotating and coming into contact with the metal table.

Mounted the bracket to the magnet using a jam nut so that it will pivot on the base.  Drilled and tapped the bracket to receive the PVC piece.

Flux core torch.

Electrode holder.

Hope this helps,

Mike

CJ7 Storage Box II

Decided to add a second storage box to the Jeep for camping gear.

The box will be a UWS 32"w x 12"d x 12h ATV Toolbox in aluminum diamond plate.  I want there to be storage under the box for sleeping pads (not subject to getting wet) which necessitates some steel brackets to raise the box.

Bought a new Century flux core DC wire welder that I've been itching to try out.

After several redesigns, this is the final drawing.  It will be secured to the bed of the Jeep by the two welded seatbelt nuts for the rear seat (which is not in use) at the front of the bracket and drilling two holes in the bed near the tailgate at the rear of the bracket.

Salvage yard steel before and after wire brushing.  That was a new wire wheel...

All the pieces were cut and notched by hand using an angle grinder.  The ends were squared up using a stationary sanding disc.

Used the existing welded-in seatbelt nut (bolt on right) and drilled hole for new bolt (on the left).

Notched the 1x1 tube to lap over flush with the face of the "c" channel.  Beveled all edges that will be flush so that they can be ground smooth.

Edge beveling. 

Tacking the "L" channel.

Welding table from Harbor Freight (very sturdy).

 Tacking the "L" angle to the bracket assembly.

 In order to grind flat, the edges must be beveled to provide a place for the weld material.

 Welded bracket.

 Flush end welds.

 Transferring the holes in the storage box to the brackets.  Cut and drilled a cross piece to provide security for the items under the box.

 Welded nuts onto the bracket and the cross piece.  This is the assembly bolted to the floor of the Jeep to confirm fit prior to paint.

 The storage box bolted on.  Everything fits as it should and is square to the Jeep.

This bar adds a little security for items stowed under the box.

 Success...!!!  Now to disassemble and paint the brackets.

 Shot from rear with the spare tire carrier in place.

Shot from side.

Hope this helps,

Mike

Storage Box I

Jeep CJ7 Storage Box

Needed lockable storage for road trips.

Decided on the UWS Storage Locker in aluminum diamond plate.

• UWS 36 Footlocker
• Overall Dimensions: 36" long x 19-1/4" wide x 12" deep
• Width Dimension (not including lid): 35 1/4" which leaves 3/8" clearance on each side
• Made up two 15" long support risers from 2" x 1" x 1/8" steel U-channel so the lid would clear the height of the wheel wells and leave some room to slide objects underneath.

Lining up the box with the front of the step in the tub behind the seats, measured and drilled holes in the channel and mounted it to the tub.  Then sat the box on the channels and marked the outline of the channel legs onto the bottom of the box.

Drilled 1/4" holes in the bottom of the box within the marked outlines, then sat the box back on the channels and transferred the holes in the box to the channels.

With the holes in the channels marked, they were removed, 5/16" holes drilled and then tightened 5/16" bolts and nuts to all eight holes.

Used 3/32 6011 rods at 85 amps to tack the nuts to the channel.  First time welding in 40 years... I'm happy.

The box is almost a chrome finish.

 It just looked too new so decided to scuff it up with fine ScotchBrite.

Hope this helps,

Mike

Storage Box II