Welcome to Jimbo's Garage. Good afternoon, everyone, and welcome back to Jimbo's Garage. Today's video, we're going to be making a custom front entry gate. This is going to have a slight radius to the top. We're going to have a couple of small side panels on either side.
It was going to have some custom decor on the inside, but I'm going to have to make because it's not available at my distributor King Metals.com. I don't know. They must be still out offshore someplace, but I'm going to have to make this to court. I've got a drawing here from the designer built by Newkirk. I do a lot of work for him and I'm going to bring in. I'm going to show you what this looks like and then we'll get started.
OK. All right. So basically, here is the design right here. You can see that it's got a slight radius to the top right here. We've got a couple of small side panels on either side. And then we've got this circular decor on the inside of everything. We've got a lock box right here and a door bell ringer box right here.
Now that right there and probably going to install after the fact. So it's just a little small box that gets drilled and installed into the side grille. But for the rest of it, what we're going to be using is.
Inch and a half square tube 63 wall thickness for the frame and the inside. This is half inch square bar solid bar stock. And that's what we're going to be using for the inside right here.
You can see that the designers provided all these dimensions right here, and this is what makes it really convenient for doing projects like this. It takes the guesswork out of it. All these have been calculated, and as long as I build it to these dimensions right here. It's going to fit right inside the the area it's supposed to go to.
All right. So all that said, let's get started on today's project. All right, so the first thing we're going to do is start by taking out the material, now you can see that I've got quite a selection of material here on the ground. This is actually for at least three or four different projects. I have upcoming all different sides of stuff here.
But what we're looking for here today is an inch and a half square tube. And I have that right back here. I got some also some two inch square tube. I got to mention a quarter, some one inch. I got some real cap for some handrail right here. And of course, this is going to be our our half inch square solid bar stock that we're going to use a little bit later for this project.
But right now, all we need is some inch and a half square tube. I'll be glad to get rid of this pile one of these days. I'm going to get rid of this pile and there's not going to be anything here but I've got a pile of material here for at least a year. I just don't have any room to put all this stuff, and I just keep stockpiling it right here.
But I'm looking forward to the day. It's all going to be gone. All right. Let's grab some of this stuff and get started. All right, so the first thing I want to do is build a gate.
The gate is about 52 inches wide. It's about five and a half feet tall overall, top to bottom. We're going to build the gate.
That's the hardest part and get that built first. And then the side panels, even though I have dimensions for those, will be double checking those dimensions to be sure that we get those built to the right size So the first thing I want to do is get the material cut for the gate. All right. So the first thing I got to do is set the old evolution on the 45. I've got some cuts to make.
You know, I recently did a video on a comparison with the evolution and the fine slugger and might have been a little deceiving. It might have showed where the evolution didn't cut all the way through on a 45. But that's not. That's not true. It actually hit the stop there. And you can see I have no problems at all cutting through. It's been a great, great song for me here in the shop, accompanied with the champion cut off Blade works really well.
All right, I've got everything I'll cut. I need for the gate section right here over my welding table. I've got my cable dogs in and I'm going to set these sections at a 90 degree angle.
You might be able to see that the skin is about five foot six or five foot eight tall. It's going to be and it's hanging off the end of my table there and you'll see here in a second the radius coming in right there now, the radius I have bent at my metal supply store. I don't have to roll it here in the shop. And so I often have these guys at my metal supply store.
They work well with me and I haven't been these radiuses and it works out pretty good. So the idea here is to clamp everything in and get everything nice to square and find the center. And then the idea is to create an angle that when you cut through the radius piece and the gate frame itself, the idea that that technically is supposed to line up perfectly and you're supposed to have a nice shine That's what I hope for at least every time I do this. But for some reason it doesn't seem to work out that way and you'll see here in just a minute. But I do the best I can, and theoretically, that's what I think should happen.
But I don't know. Maybe my math isn't right, or maybe I'm not doing it right. I'm not really certain. Well, I've made my mark right there on both the radius piece and the gate frame, and now it's time to start cutting these things off. All right, so for you safety, Sally Sara, you might want to turn your turn away.
This is a big no-no in the metal industry. You can see that I don't have a guard on my cut off wheel. This is a six inch cut off wheel that I have sat on my four and a half inch grinder. I use it on occasion. I don't use it all the time.
But in situations like this right here where I need to cut all the way through on an angle, it works the best for me rather than turning this piece around and trying to cut all four sides. I've been doing this for a long time. I've never had an issue with any blade coming apart or busting or disintegrating So I've got a lot of confidence in this right here. I don't recommend you do it, though, if you don't have experience doing this. The best thing is to use a guard.
All right, with everything all cut. You can see that a piece and everything together, and there is what I'm talking about. I've got a huge gap and I don't know what it is because I had everything all figured out.
At least I thought I did, and I just still ended up with a pretty sizable gap, specially on that left side right there. So nevertheless, I'm not too worried about it. I'm just going to go ahead and clamp everything down at the dimensio I'm trying to hit exactly, and I'll figure out how to fill up that gap here in just a minute.
You know, one thing about lock boxes here, and I've installed these several different ways. I've built the frame first and then cut the cut the side rail off and installed the box. And that doesn't work too well because that actually has tension in the gate after you pull it together, when you cut that open and it kind of springs. And I've never been able to get it straight, perfectly straight.
This is the best way that I found works for me. Before you weld everything together, cut the opening. And I'm fortunate enough to have a woven table table dodge to keep everything nice and flat.
And once I've got my dimensions and everything hit exactly where it needs to be, then I just go ahead and start well and everything in All right, so here's here's a here's a little pro tip. When you've got a big gap like this, you can see the different filler rods there. This is 18 fill a rod. And then I've also got some 36 round bar stock and some quarter inch round bear bar stock. And I'm going to be switching around from all of those, depending on the size of the gap. And you can see that you just kind of stitch those in a little bit.
And, you know, it's kind of an ugly well, but it doesn't matter. It's all going to get ground down and cleaned up, and you can just see this is the eighth inch bill, A-Rod that kind of just fills that gap a little bit This one right here is a big, yeah, nice quarter inch, and I just fill that whole thing in right there and we'll get that fixed up. All right, with a little bit of Mercer ceramic wrapped up right here and start grinding and cleaning the welds up. That's the way I like to do things.
I like everything looking nice and nice and smooth and finished. But when we get to the bigger gap areas, sometimes it takes two or three times to go through there and fill in the areas with the weld. But here's that, here's a good example.
Now that's an ugly well, and we know it is because I had to fill a bunch of big gaps and I knew it was going to be that way. But I'm going to fix that all up here right now. I start with trying to grind everything and start shaping things up where it needs to be. But sometimes you've got to go back several times with the welder and kind of fill some, fill in some lower areas or, you know, whatever needs filled in to bring it back flush. You can see here there was a lawyer right there, and I'm going to take this down and then actually had to hit it again.
I think there's a couple more times before I had to get it just right. I was a little hole I created, so it gets kind of thin. So this is when you grinded things down and sometimes it goes burns through. You just got to fill that stuff in as starting to take shape, though, you can see it's cleaning up pretty good.
And after all that, it did work out. And here's another example of the same thing. And I use 60 grip flap just for the most part, that seems to work the best for me. You see, you get on the backside.
I got a little bit of a divot there. I want to fill that and then I'm just going to clean that up there and just shut this And that's moved up really nice. And that that intersection there turned out pretty good. OK, so what's the gate frame made now? It's time to work on the decor on the inside of this. Now, before I started this project, I noticed that if you remember from the picture, there are some long oval type of décor that goes in between all this.
And I look to my my brochure or my catalog from King Metals.com, and I did find I did find something similar some. This is what they have to offer right here. Obviously, I think for typically for like a handrail or stair rail or something like that. Now the problem with this is it's much too short right here, and these are just different lengths and they're not the right size. So I thought, I'm going to get a couple of these modified to see if they're going to work for what I'm doing. And if they do, then I'll go ahead and just order the rest.
And this is what we use and I'll just modify these. Well, I got this is the this is what they look like originally. This is one I did modify it. And here's what it looks like modified. Now we're getting closer to what it's actually going to be going on inside here Now these things are supposed to go on here. And of course, the tails are long, but not the right length, but this is about the right leg.
So I decided this worked pretty good. So with that said, I'll go ahead and just order these and I'll modify and make work well when I call down to King. No. None of them were available on any of the facilities Atlanta, Baltimore, Dallas for here in L.A., they had none. I must have got the last two that they had in the United States, and they had no idea when these were going to come in.
So I had to go to game plan number two. So I went over to my metal supply store and I asked them if they could bend some circles like this and kind of replicate this a little bit. They said, no, they didn't have the capability for that.
So now I'm a little bit stuck. Not certain what I'm going to do. And then it dawned on me. I'm in the concrete business and I've got a rebar bender that I have that just might make the bench when we've been hooks and cages and rings and stuff for rebar out in the field. We make these tight bends, so I'm thinking maybe I can make it work with that. So let me bring that in show to Dallas like and we're going to give this a try.
Oh, all right. So this is it so technically what I'm hoping I can do. Yes. We'll cut this half inch solid square rod bar, whatever you want to call it, and it may be five foot lengths. We'll stick it in here. I'll see if I can make a bend and we'll get two of them together. Cut it at the right length that we need. Well, those together.
And then we'll just make the right length for these out these tails on either end. So let's give it a try and see if we can make that happen. All right, so this is where I'm grabbing the half inch square solid bar stock, I'm just going to grab a few right here.
Get it over to the cut offs off and they come in 20 foot lengths and I have them at the metal supply store cut him in half for me. So it's easy to get on the truck and then we're going to cut them in half again here in the shop. I'm like, cut in three at a time right here. I just don't want to overload the store too much, although I'd never really had a problem, but we're just going to try this out and see how it works. All right. Got we got six pieces here.
Give it a try, I've got to cut in half. All right. Let's get this thing here. Set up. All right.
All right, so this thing here has got 45, 91, 35 and 180 degrees. We're looking for 180 degree bend right here. So I'm just going to set this to 180 degrees. Um, they have rollers in here that are interchangeable. I've got this one chance where it looks like it's a happy arch and this looks like about a four inch radius, if you will. Some think this is going to work.
Got stops here. I'm going to turn this around because the switches on this side from a. Like this, so I can see what's going on here. I've plugged this thing in. Let me mark these things in half.
We'll see if we can make a pan. They don't have to be exactly in apps. These things are about five feet. I'm gonna go right at about 30 inches.
I'm just going to put a mark roughly right here at about 30. It doesn't matter because if these things do man, and they do make the band and it works for us, I'll be cutting these things anyway. So. All right. Stick one in here.
Now, I've used this thing a ton of times from making plans on rebar so I'm pretty familiar with the way it works. It's been a while since I've done a 180 degree ban. Most of our vans are 90 degrees.
It might be kind of sketchy on this and right here as this thing swings around, I don't know if it's going to swing too far. I might have to watch my hand here. All right. Let's give this thing a try. Let's just see what happens. Well, would you leave that? And that is almost perfect, right there came up a little bit short, not a big deal, probably be able to fix that. That's just that's actually pretty close right there.
But you can see how sketchy that got and it came around and I don't know how close it was. I mean, I'd like to be able to hang on to it right here so it doesn't jump out of the machine. Maybe it stops before it goes all the way. Let's try one. I want to hang on to this little bit longer, and let's just see if it stops, I'd like to be able to hang on to this thing and keep it in the machine as it makes the band try one more time.
Yeah, like, yeah, huh. Yeah, it is almost perfect. Well, that was easy. So the idea here then I don't know if you can see this at the top. But we got two of the put together. We got to have an event now.
So now what I got to do is I got to make these. I believe they're 42 inches long, so I'm going to measure 42. I'm going to mark and mark them and I'll cut them. Well, those together and then I'll use the tails and I cut off for the ends on either side right here. And that should work for this right here.
I tell you what, I need a bunch of these while I got this thing going. I may as well go ahead and just bend up these four right here. We bring in a little bit closer. We get a little bit different angle on how this works. I put some gloves on just in case I might get a little gnarly. All right. The four more here.
Take him in there and see what happens. Now, hang on to this. Okay. Perfect. All right. Another one, after doing a couple of these that it was really, really kind of simple and that was really come together, pretty good.
Some of them got over just a little bit. But, you know, for the most part, it didn't take too much to just open them up or close them up in order to make them, you know, a perfect blend. For those of you wondering, this is a better Newman vending machine, it got this several years ago saying works really good for rebar and obviously works good for something like this. All right, I got all the pieces bet right here and now it's time to start, you know, measuring and cutting. And I know I think I said it was 42 inches, but I believe it's 48 inches is the opening that we need.
Now I'm just trying to see be sure that this is going to work the way I want it to work before I cut everything So I want to put one together right here. You can see I'm having a little bit of trouble in the store right here. I didn't want to cut through both of them.
I had to watch that, so I figured out it's better to stick it. In the back half, I got a little bit more room and I had keep you from cutting all the way through both bars. All right, so I got everything all cut our leaves this one and you can see that I've created a jig right here and I've got everything fastened down. With fixture clamps right here and the table dogs in this kind of a jigsaw, when I get to go going on these things, I can just keep putting them in there, clamping them down and just and just complete the process.
With everything clamped down like this, nothing moves around, everything stays nice and straight, and I can guarantee yo that I'll have every one of these pieces exactly the same. It's a test piece, I just want to be sure everything is going to work out before I go ahead and do all the rest. And there it is, I will do the one side and ground the wheels down, and now I'm hitting the other side right here and I'm going to clean these up. There's a little bit of gap between. I kept a little bit of gap between there to be sure that we get some filler metal in between all that to help pull it together. And there it is now.
Worked out pretty good. Well, that said, now I know it's going to work. So I've created a jig right here for the length that I need. And it's just fast.
You're able to just put them right in there like this, and I'm able to mark everyone went pretty quick. I have a couple of side panels that go along with this gait. And so I don't know. I can't remember how much I need. I think I needed like eight or nine of these things or ten I can't really remember. But, you know, just setting up jigs like this makes things a lot easier for you and a lot faster.
It doesn't take too long to set something up and then over to the store and get them all cut. And once I get them all cut in, it's time to start assembling them. You can see that there's a lot of a lot of cuts that have to happen. And I've got all these pieces and, you know, all kinds of different way of getting them in there to be sure that I don't cut through the other side . Different ways. Different angles. All right. Time for the assembly.
And like I said, this clamp everything and the jig after everything is all cut. Clamp them all down. Be sure the distance between everything is just right. And I know it's a lot of clamps, but you know, you got to do this in order to keep everything straight and be sure that all these pieces end up being the same. So I got a lot of these to do so, I just want to get through and get them all done so we can start the assembly.
All right. Both score pieces of all the on the interior decor pieces all done here trying to get these things lined up, getting in their place. I did have to do a little modification before I did this. I had to extend this box about an inch on either side that brought over the hardware that's going in here and it's got some elongated box on the on the outside.
So I had to extend this. I did that off camera, but basically just out of the piece of inch and a half by one inch square two to it and fill it in, just ground it down. Just extend the boxer. All right, so the one thing about this, you know, using this half inch solid bar and that.
And that's it's good to make this gate really kind of heavy. So not only do we have this going on, we also have solid bar straight pieces that are going to be going in between all of this. And you know, that's going to make for a pretty heavy gate. I like using the square tube that would be like a hollow two tube rather than a solid bar.
It would have been a lot lighter, but I've never been able to make this down right there with the tube. So that's why that the design of what was a solid bar like this? All right. But get these things lined up, give spaced out correctly. I just got to make a couple trims here at the top of this, and then we'll get these things to hold it in. All right, well, everything all lined up.
It is just time to cut these tails off the right at the right length, and you can see that I numbered one through five or one through six, however many I had right there, it looks like five. And then I'm just going to cut this off. You know, a lot of people ask me what type of angle grinders I use, you know, for the most part. I've got these Walter technology grinders, and I'm telling you what? These things are super high quality.
They're not a sponsor of mine, but you know, they're pretty pricey. But man, they're really good quality. Now I have several of them. I've got several different kinds of them. But boy, these these, these are the best. All right. You can see what I'm doing right here, and so I'm just cutting the the pieces of right here, and I cut the other side off as well, and they just drop right in.
I'm trying to get them all lined up here and you can see I use these spacers to. The idea of the wood spacers is to lift them up, to get them in the center part of the frame. I have all different sides.
I keep my wood scraps and have all different sides of spacers. I use them all the time. Well, everything is all standard up and I'm just going to go ahead and start welding in place. Now I am when the world is all the way around. I don't know that I'm going to show me doing all of that, but it I definitely welcome all the way around. I didn't want to bore you guys with it with all of that, but I think you get the idea of how it happens.
Everything is lined up. Everything is, you know, nice and square and this gates starting to take shape. It's starting to look kind of like like the drawing that they had.
All right. And so this is the intermediate pieces. This is the straight barge going between everything. This is per the design and it's the same thing just spaced everything up and get the dimensions equally the same. And then, well, those in-between. You know, I build a lot of gates here in the shop, and all of them are different. Nothing's the same. Everything is different and that's what that's what I enjoy about what I do here.
You know, I never seems it seems like I never build the same thing twice. Sometimes you're close, but the never the same thing. And this one right here is a unique design. This builder built by Newkirk comes up with some really good designs, a lot of different things, and it's really enjoyable working with them. All right. Well, that gets all in, and it really looks close to the picture.
I do have a couple of side panels to build right here. I'll show you the one. Yeah, basically, it's the same thing. The thing is cut everything as fast and down on the welding table. Nice square.
And it's the same process just once everything is clamped into place and then just, well, everything in. And once everything is well, then just grind everything down and smooth up the edges and clean everything up. Now this is the bottom part of the panel. You see a tale there at the end, probably about a foot of this is going to go in the ground. The bottom part of the rail right there is about two inches off the ground and the rest is going to be in some concrete.
And then it's also going to be attached to the wall with some tabs and there will be another panel just like this one on the other side. You know what, it's this was really enjoyable seeing this come together. This is really a fun project. I really take a lot of pride in doing this, and there's a lot of satisfaction that I get when I see the final product right here, and especially when it all comes together and gets installed.
And just like that, that is what this panel looks like and it's what the other panel looks like as well. Just some final welds right here to complete this project. All right. This gets done, gets off to the powder coders, and then we're going to go and get this thing installed and this is going to be a finished product. I hope you guys enjoyed watching this video. I hope it was educational for you.
Thanks for watching. We'll see you guys next week. See you next time on Jimbo's Garage. See you next time on Jimbo's Garage. See you next time on Jimbo's Garage.
2021-11-27