It all started with a decision to purchase a new boarding plank and after measuring up it was found that it wasn't going to fit the roof furniture, it needed to be wider. This is where I come in.
This is what I did:-
Remove the furniture from the roof sealing the holes with CT1 sealant, and take to my workshop.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhX2neLfNTTlZTlyWUpjiu01d6slspoeAkylWxqhtuHXiXlGMlOEXrh4KQNAuTtenP7r_8jtZd3qojNzl_cc4QHYKIfzbNFipQ-HiiLIEXmw6asFMKRFG5QPgmB0T-8sDxIFtGRXpEpNHu0/s400/20190314_120711.jpg) |
Removed from the roof to my workshop. |
Start with removing the rubber gasket from the feet using a scraper and a file to get any burrs removed. This will help to seat it flat on the fixture.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmPVkSTCtr0l8O7WWWuiQIW5cXfeTugli6kRlhPtCGdLBXakbASTF-K62rslOH8Nn4A4t50UwFpACGwdUuuooCiYTfyWVzpVZRKsDv9qogTgQZdx_vd6KdY4RlDXcyOpaRyttE_Y-LtfNd/s400/20190314_120930.jpg) |
Clean and deburr the feet. |
Make a fixture using a piece of mild steel. Drill and tap four holes M8 through the steel and attach the furniture using four M8 cap head screws.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-YatPvC59A9Hm6D_H6ewKR8Onrt9t1oohpu-w4jJeL9VntISVyUfRZVuFDMWYlXIN-WWKakfgUhUFil98GtqkgyC-2qKkCBSXKbGqjhKTcaXDkVeWMo9HXjqUvWI8DCklc22-WmogFcAl/s400/20190315_115926.jpg) |
Drill... |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9tRVLkNB21XSePX5TorF9xuK3ZyQ8I6NFLnEF87IcAyXzvBFMYHKocV0sIR8qJxscN208EqAwaJEquur9rR0Eg6-_3GARz7MjfWUl0isZSyEgaMDR7HocTt1ki6rztlqBP7eo38mZ3tPW/s400/20190315_115037.jpg) |
...and tap M8 through. |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQnYM48TkkYed2wKY9clrj5pTMBgaPgUlGFKJSjkbA9IXNenew4wgA8AScjxu9qrCOBKoaO31Ux9u9QJLdYBb8Ml9x6Uqa8N07GKj-2aXC-xpLQa4iA6A10pRpypQakZ_XwH3Lr-2XSATQ/s400/20190315_114123.jpg) |
This ensures hole centres remain the same after extending the upper part. |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh9c4l0jk4RXM4a-6GeIX0MkrEk3LIWxt9eNziGzv2pNpKkPU7EK0Q6SuVxiR_PorS1Ja_Z5HpjMXo0b8nx-lel0ZKnoPjCU6_LLbN152NZbjAAvfaJn_6PfUwRLhqyt7fBp6JzH19DpwF/s400/20190315_114137.jpg) |
I later changed the countersunk screws for cap heads to provide a little flexibility. |
Next I milled the spacer blocks I'm going to use to extend the framework.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7SF8cVImQlQZPHIC6QB1-_Zu3WXmpMMq01rWn7AC9JVQSbV78Edfl7M15s_Zc-_a6_kozlBwOVOpYKCslDKkUV6a_88KRDBxKF8Stx8fFghkzHBaYVg8tUgIbybpWTu6AQV6K4zKGsIrC/s400/20190315_093849.jpg) |
Mill this end to clean and mill the rebate, then mill opposite end to length and rebate. (For the eagle eyed, I did square them up in the vice before machining). |
Cut the feet off with a hacksaw leaving them attached to the fixture, and then cut the remaining part in half.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqhLFEe_pgG8GqH85z8kduEJXROb3tMEHWuK2vpFUX4xuLmHEhJGvRzp2lzzvx7Pgh94lYBL_aSMgblseS2bGshH6eq7Oj-SxXMLd9hz8hJBcuPrt-GltHnEre7mM8i80oWLLJqiCkpt4s/s400/20190315_122557.jpg) |
There's no going back now! |
Mounting upside down in the machine vice, mill the cut face to clean and then mill a rebate to match the block. Then do the same on the other half.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaanWgrsHWsCKfDAu8blC6tDdkafcXP1eOOwYaWgOEkIF04hBNg0TTb0gcy2dlqmyy66AhJPghAOv7tXLBbep2V_zWLrP7qJTX1dHgmWos3DwtDAG0-PlvvBtlRh4YD4ZfjU9v8GPUggyw/s400/20190315_123704.jpg) |
Machine a rebate to match the block. |
This is how it should fit together:-
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAcXAWF4Ww0U7EKCMm4-gzRkC2Wd_myPhJVdKaU5cV7584XUPRe5OUCehdBCEsrk6VcrDAa_RZL7XNYwG9uhXz6IIYJx9hCnU_wObhot8JpW6l7pZBwjTgBVDw9V2-00KpIi41SnBqIEYx/s400/20190315_124908.jpg) |
It's ready for soldering. |
Set it up in a make-shift fixture for soldering:-
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNB8satvO3O1OZ91INgNEEowG1xacBcq2gTW8x8pXoW3dePBPepxtkXa2eQYpiEBnFzRCYT4YoATpU97cgMAtwGoqrxnkZgQPdXSTVMNYofmRtNKrJLsojDuDt8-oMsrrcQvMkrVNL0zpE/s400/20190316_112936.jpg) |
Silver soldering the joints. |
The metal is so big it acts as a heatsink so butane/propane wasn't going to be hot enough. Enter MAPP gas. If you don't know, Google it.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4Jq__-p_WPzp6sGR2k9P7VtgLd966Apq7Fp5I5-FPDuPFh5W7nuqKnhPVTuwRIIG69HTRpt3-O0D0s_Y54xVcgOXpADbIoNmhGyQq58c_IUgw0fv7iDn11FfNer0Ob8isJSZAAo5uvv1M/s400/20190316_130420.jpg) |
First two joints made. |
Another make-shift fixture required to solder the top bar to the feet whilst the feet are held in the spacing fixture.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaf8LtaZMkis_DU_w1PAN4taHyF6yinZvxgi3r9pep5tQiHf_0bTDUvSVtAM6q1QF22fg4vGDJMteKWJjq4fiuGiglS0m04hzWvCGpg7xXbB7G1bvWicYPVBAl3TVd5KqGH4mqai4eJoq4/s400/20190316_154855.jpg) |
L/H joint completed. |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPecaJklVHtSBH00rxWtD97mlifqeGSXUHnfZzJZk1vqYiA5TAZRD8ZKPJ5pIeibYzVvKAnowYvguRc7DGV9xcPWOVc9SGmQetyUwRqFhcfluhxcRDWnPEsF9p-iiXnIzKgV7UaZcy9BCk/s400/20190316_155059.jpg) |
R/H joint completed. |
And here it is, just needs a bit more cleaning and polishing and a coat of lacquer.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjncYlqg9r9hm3b59LVPoodz9oGpdq4KxKZWja32lb-TnTRHx4tgpvOTaGKescMWRwtX-LUHDmWhXBYaERyrwryVQai8zsld7TdIGDZot676wgyyFkdzK2NVPLEUUfWaKZ0_96U4JlKZ9eM/s400/20190316_175325.jpg) |
The (nearly) finished item. |
Now I have to do it all over again for the other one. 😉