We are a nation of home lovers and DIY enthusiasts, of that there is no doubt. Many people gain great satisfaction from carrying out their own projects at home and working to a very high standard. For most people, DIY only extends as far as garden landscaping, decorating and woodwork around the home.
There comes a time, however, when most jobs become almost routine. When they offer no challenge, boredom begins to set in. Lack of enthusiasm for the job in hand can often lead to a poor level of workmanship and dissatisfaction with the project as a whole.
Are you ready to take on more of a challenge?
Maybe there is a wooden handrail in the home or garden that looks old and shabby. Replacing it with a bespoke steel alternative is likely to cost a packet, unless you build it yourself.
Now, you may think that it is beyond your capability, but with a little practice, it is possible for the keen amateur to fabricate a modern masterpiece in no time at all.
If this has sparked some enthusiasm in you, read on; you may find that you can do more than you imagined.
The Design Process
Draw your design on paper initially. The easiest way create your masterpiece is to know what standard materials are available to you, and work with them.
Next, go online and look for a company which supplies steel tubes to fabricators and manufacturers.
The tubes come in various shapes, including:
- Tunnel Section
- Round
- Flat Sided Oval
- Square
- Rectangular
There are other shapes, or even solid bars that can be incorporated in your design. When you know what is available to you, sketch out your design, then draw it to scale. You should produce a cutting list that includes all pieces so that everything can be ordered.
Construction
The finished product will be better if it is welded in sections. There are two main welding methods that anyone can try. They both work on the principle of using the welder to complete an electrical circuit.
At the point where the circuit closes, incredible heat is generated that is then used along with a welding material to melt and fuse two pieces of metal together. These are:
- Arc Welding. This method creates an electric arc between two pieces of metal. It is not suitable for welding thin materials usually, as it is too powerful and blows holes in them.
- Metal Inert Gas Welding (MIG) is the favourite choice for most amateur fabricators and will suit this project well. A continuous wire electrode is fed to the weld to create the arc. It is shielded by an inert gas that prevents the weld from becoming contaminated.
The different shaped tubes must be cut to size and the ends must be shaped so that they all fit together well. They must be free of any contaminants (usually the joints are cleaned up with a grinder) and clamped together. An earth electrode is then clamped onto the piece, and welding can begin.
Finishing
When construction is complete, a finish is applied to stop corrosion. There are many options open to you. You may paint the handrail yourself or send it away. Some options are:
- Galvanising
- Chrome Plating
- Zinc Plating
- Powder Coating (plastic)
When the sections are returned to you, the last job is to install them. You will then be the owner of a one of a kind rail to be proud of.
The finished quality is entirely dependent on the time invested in the project and a patient approach to it. This project, however, is not beyond the capability of anyone willing to give it a try, so reach for your pencil and paper now.