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.
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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.
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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.
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Drill... |
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...and tap M8 through. |
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This ensures hole centres remain the same after extending the upper part. |
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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.
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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.
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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.
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Machine a rebate to match the block. |
This is how it should fit together:-
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It's ready for soldering. |
Set it up in a make-shift fixture for soldering:-
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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.
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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.
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L/H joint completed. |
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R/H joint completed. |
And here it is, just needs a bit more cleaning and polishing and a coat of lacquer.
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The (nearly) finished item. |
Now I have to do it all over again for the other one. 😉