After fabricating a hand sample for the architect to communicate the construction method, and making some test cuts into the proposed material thickness, I was able to order the 1/4″ thick mild steel plates needed, and started the process of CAD layout and CNC programming. Here are the pictures to show the fabrication of the first of three wall base plates for this project!
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This is the sample for the architect to show how the vertical MDF slats will be held in place by the base plate. -
The MDF slats are secured with a thru bolt for ease of installation. -
A couple test cuts into 1/4″ mild steel plate. -
A couple tabs for testing. -
The tabs are welded from the bottom side. -
This will keep the top clean to slide the MDF slats in place. -
Starting to cut the slots of the first base plate sections. -
The base plate is cut in 3 sections and will be welded together to accommodate the shape and overall length of 23 feet. -
Because of the weight of each piece, I’m using the jib crane to get them off the plasma table. -
Cutting all the tabs needed for this section. -
Starting to set up for welding the sections together. -
Some grinding to prep the welding joint. -
After welding the top side. -
Cleaning the weld bead and grinding it flat. -
Repeating the process on the other side. -
Welding the back plate together. -
The pieces are long and heavy! -
Setting up a welding jig for the next step. -
Here are the base plate and back plate set up in the jig, ready for welding. The area of the stitch welds has been beveled for better penetration. -
Starting to clamp and weld down the edge. -
All the stitch welds are in place. -
Thanks to my mobile material stands I am able to lift and move the pieces around. -
Nice and square. -
Setting up the tabs for welding with little magnets. -
Welding all the tabs from the bottom side. -
All the welding is done on this one. Two more to go! -
Its 23′ long and the weight is about 330 lbs. Its a lot for a single guy to handle, but I got it done!