hi welcome to weld.com i'm beau wiggington and today
we are going to be making some new rails for the front of our house
so my wife she would really like to have a railing that connects these two pre-existing beams
so that is what she has designed so the top and bottom pieces are going to be solid rails we've
got two dividers here in the middle the cross sections are going to be our rounds and then the
boxes in the middle are also going to be made out of the square tubing and i'm going to be notching
those out so it fits snugly and i'll show you how we're going to do that here in just a moment
but if you're anything like me you might not always have access to getting a full
bar so you have to get it cut down at the steel yard so what i'm going to be doing
is finding out how to remake the entire bar out of these 72 inch pieces
so i've done my calculations here and the top and bottom are going to have to be
136 and a half inches and so to get that i'm going to weld both of them together
but we're going to be taking 7.5 inches out of one of them to make sure it is the correct length
so i'm gonna do that right now so this right here i'm just grabbing those measurements going across
next we're going to get the measurements of how high it's going to have to be
so what i'm getting right here is going to be the measurement of the height of the actual rail
i want to make sure that it is going to look nice with the pre-existing rail we have here
so just making sure we're going to line it up flush with this other railing so what we're going
to do we're going to be getting our measurement here what i do with my soapstone is i grind it
down into a nice little point here that way when i mark out where our seven and a half is going to be
take my straight edge i'm going to butt that up against it so we have a nice
straight line nice right exactly where we want it to be measure that again to make this
be exactly seven and a half inches what we're going to want to do is actually cut it
right on this side of the line so we're not going to take off extra material with the chop
saw the next thing we're going to have to get are these measurements here which came out to
28 and 5 8. so we're going to mark out two of these on one we're going to cut those out
28.
so that one we want to make sure we are cutting right on the line so that it is the right length
today i'm using the lincoln electric 210 mp
uh my wire feed speed is at 185 and my voltage was set at 17. here i blew a little bit of a
hole because the fit up wasn't 100 correct so whenever you blow a hole just wait for that
metal to cool down a little bit and i'm just doing small tacks to try to fill in that hole
here i'm using a flap disc by benchmark abrasives it's going to be an 80 grit flap disc i'm using
it to try to blend the metal together so it looks like it's always been one solid piece
so we are just about to weld in one of our first dividers we're going to divide this railing up
into three and then put our kind of intricate design in the inside but as you can see right
here we've marked our center line we know it's one inch tubing so we got half an inch
marked our tube there our first uh divider the center line for that is going to be 45 and 3
8 so we have that marked here and just line up center to center and then we're going to
go ahead and tack it up weld it out and then we'll attach the other side and go from there
here i have my two armor tool clamps the thing i like about these is that you can clamp them
down with one hand and you don't actually have to adjust the tension on them it just automatically
does it but i'm using them to clamp everything down so we get a nice flush fit with the top rail
and the divider so quick way that i've learned to just miter quick edges is i take a couple pieces
of scrap angle iron i tack them to my table at the desired angle right here i've got a
30 degree angle from the end of this left one to the end of the right one got that 30 degree angle
and then i actually just stick the material in there i'm gonna go ahead
and clamp that and then i take a grinder and just shave that on down to the desired angle
uh
so
so here i've already drilled a hole that is going to be 3 8 and now i'm actually taking a tap that's
a 1 4 tap drilling it into the hole so i can put those threads in there that i can attach the bolt
this is the same process over on the other side you just want to make sure you take this nice and
slow but you don't want to go too hard on these because sometimes you could strip out the threads
all right our railing is all installed we went ahead and bolted it to the pre-existing pillars
and we drilled holes into the concrete using a hammer drill and then used some anchors to
secure the bases we changed the design a little bit my wife wanted a sleeker look so we got rid
of the boxes we were gonna do on the inside and just went with the dividers as they were
but if you have been in the pickle that i was in where you're working in a small space making
a bigger project and you didn't really realize it until the end tell me how you fixed it in the
comments below also go over to weld.com become a member there's tons of forums over there tons of
people to ask questions and i'll be over there too so until next time we'll see you out there
you