Aluminum Boat Mast Build | JIMBO’S GARAGE

Aluminum Boat Mast Build | JIMBO’S GARAGE

welcome to Jimbo’s garage welcome back
to Jimbo’s garage well I’ve got another good one for you here this week we’re
gonna be building an aluminum mast crane for for the back of a houseboat it
might be similar to a dabit crane or add a bit lift the idea is going to be same
it’s going to mount to the back of the boat extend out and be able to pivot in
and out and on the end of this mass is going to be a satellite dish for a TV a
little bit different but does give me a fun project all out of aluminum this is
three and a half inch schedule 40 round tube three inch schedule 40 round tube
but that’s um one inch round tube schedule 40 also we’ve got some three
quarter inch aluminum plate all aluminum project yet again testing my aluminum
welding skills the great project let’s get started on today’s all right so the first thing I’m going
to do is trim up this flat plate to size and you can see I started off bad right
out of the chute that blade was starting to creep off to the side so I jumped
into this Mercer aluminum cutoff wheel right here and this is something that
I’ve never used before you know you use a lot of cut-off wheels and you know
they all work pretty good but when he gets to aluminum they never work well
they load up but this one is designed for aluminum and I got to tell you I had
no problems it cut through this just like it was cutting through metal the
blade never loaded up I could have made it with one blade right here but I
decided that I was just gonna play it safe and jump into another blade you see
there’s a lot of life left in that one but I just changed a new blade and it
was just a matter of seconds and that piece came right off of there didn’t
take too long to do that either I just jumped over the burr King and kind of
softened up the edges and cleaning it up a little bit smooth things out and make
everything you know nice and square square as I could anyway it’s time to
drill some holes in this now you know this thing this is the only size plate
that we could possibly use we’re at our maximum capacity right here I’d like to
have had something a lot bigger wider and longer to support this mass but this
is all what we had room for here on the boat so I’ve taken advantage of it as
much as I can I’ve got six mounting holes right here this is gonna be
attached to I believe some 3/8 by 3-inch long lag screws a stainless steel and
hopefully that’s going to work out pretty good now this is a hole that I
need to put in the center of the baseplate the mass the round part of the
tubing is gonna go right over the top of this I got we got wires that are gonna
come up through the bottom of this to get out to the end of the mass for the
satellite dish itself I had such a time trying to drill this hole through this
aluminum with this hole saw I just understand why it why it was took so
long but it did once I got through there just took this little deburring tool and
cleaned up the edges that worked out really good and then it’s time to start
cutting the pieces for the mass you know this is the three and a half inch piece
I’m using for the top part and then those would be the three inch is gonna
be sliding inside of that it’s a pretty good fit
as tight as you can be you can see that I’m gonna start right here by putting
the vertical piece on the on the base plate and you see a piece of aluminum
wire in there I just tried to get everything nice and plumb and want
everything as plumb as it can be of course we don’t want this thing run on
an angle I’ll put a couple of tacks in there and then I just went ahead and put
the first pass I decided to do a three pass method on this right here just for
fun so that first pass went in there pretty good this is gonna be connect
wick fillet there’s the second pass may not be the prettiest thing but and then
the third pass over the top of that you know if you haven’t done an aluminum MIG
welding it’s not the simplest thing but that takes a little getting used to
now this is the a pipe template also for Mercer industries and you can see that
be able to put that snap it right on there and and make the template right on
there and now I’m able to to cut this off perfectly for a perfect fit once
again a jump right to the aluminum cutting cutoff wheel this is you can see
how easily and effortlessly it cuts out aluminum and right on the line – you
know it it’s really good it minimized the amount of you know filing that I had
to do a grinding they had to do to make this fit fit pretty nice put a little
tilt on the yo slice right there to make things a little bit easier for me to
access and then a ceramic wheel right here to go around and clean the edges up
and it really wasn’t much I had to do other than just take the the burrs off
for a pretty good fit you can see I slugged slid that piece of frame in
there and then double check to fit and that’s not too bad I’ll go with that
and then here it is I had to drill another hole in the side of this to
accept the wires that are gonna go now up the mass and then through this part
of it and out to the very end again a little bit of a challenge surprising way
to get that hole in there but ultimately worked out pretty good alright so now I
know everything’s gonna fit together when we take this thing apart we’ll set
the that part of the mass down for now and then we’ll take this line everything
up get the holes right where it needs to be get everything perfectly square I’ve
got to clamp down on either sides and nothing’s gonna move
around and tact everything nice and square ran over to the bandsaw with some
quarter-inch plate and cut out some gussets you know I want to gusset this
thing up as much as I possibly can to limit the amount of flexing that this
thing is going to have once it’s installed I take advantage of just about
as much as I possibly could just get it all blocked up and tacked in these two
gussets right here you can see I ran all the way out to the very end I’ll out a
little bit for that cap on the very end and once everything I double check for
square and everything is nice and square nice and plumb then I want to add and
just started welding you know everything out and like I said you know aluminum
MIG welding is just is is a little bit of a challenge if you’ve never done it
it’s not it’s not your ordinary welding once you you know you get this all about
the settings you got to get everything just right in order for it to work
fairly smooth and I think that I finally I finally got it here after playing with
the settings I got into a position where it’s working out pretty good you know
I’m starting to get a little bit more comfortable with it I ended up with four
hundred twenty-five inches a minute and about twenty two bolts right here and
I’m running forty forty one thirty five thousand Swire on this and operating off
the pro pulse three hundred here and that seemed to be where I landed and
everything seems to be working pretty good with that one note is you know I’m
running pure argon at about a forty-five cfh so you know that was another thing
you got to be sure and get a lot of gas coverage in there and so I’ve got that
up to between 45 and 50 cfh but there’s the finished product can see I’m getting
a little bit used to it and you know its settings you know it’s working out
pretty good there alright so I got the main frame or lift or whatever you want
to call it all welded out for this particular project
all the major aluminum part is all done all the supports are all done I actually
have it set up above had and on the ground right here as it
would be where it’s going to be mounted I’ve got the TV dish butter on the end
of it up here I’m going to show you all that here in just a second I got a few
more things to do I’ve got some some bracketry that I have to make to support
the motor housing out here in the end I’ve got a diagonal pole that I’m going
to put in here for some support to support the weight that’s going to come
down on it miscellaneous few things left on the staff and we’ll give this project
I’ll finish up so let’s let’s do it alright so this is a this is a two
little brackets that I’m going to kind of make for the diagonal pole that’s
going to go or diagonally it’s going to go in there to support this thing this
is just some rectangular tubing you can see I’ve just created a little radius
right there and I’m making the two brackets I’ve got a I’ve got to drill
them out right here and so I you know because the parts are so small I went
ahead and just you know making them both onto this
it’s about papi eight inches long it’s just easier for me to handle so I
started a pilot hole right there and both of them and then I jumped over to
this step drill now I don’t use these things a lot but I’ve got a few of them
and I just thought this was pretty cool right here you know yet it’s got
markings on it the size you you want to go to on each step and that worked out
pretty good I just can’t ran it down there because I’m not used to it I ran
it one short right there and had to had don’t put it up but perfect deal that
worked out good for our luminol you know it’s just something that I don’t use
very often it’s a perfect setup now to get over the band saw and just cut the
braces out right there cut the radiuses out take it over the burr King and just
kind of clean it up a little bit you know those after cutting with the
advance all the edges were a little bit you know sharp just cleaned it up this
is a 45 degree angle you can see this is the first piece it’s going to be going
on a piece of half inch by four inch angle iron and then the other piece is
going to be welded right to the tube itself
here’s that angle iron I’m cutting it right at nine inches the same width as
the base plate and this is gonna be mounted about a foot away from where the
base plate is actually going to be mounted it’s gonna be am out on the very
corner of the of the boat itself it’s the sys angle
iron I’m just drilling a couple holes on either side of the angle iron to mount
it to and then this little brackets gonna go right here in the center yeah
I’m just gonna well this thing all the way around here and that’s gonna support
that pull a little bit nervous welding that eighth inch to I want to say half
inch plate but with the MIG welder right here but you know just like regular mega
I kept most of the heat on the thicker part of the plate and that worked out
really good a couple gussets here on the bottom part
of the mass you know again I’m worried about flexing this thing you know
mounted down a lot of weight hanging off the end so I tried to gusset this up as
much as I can I’ve actually got two gussets here and I’ve got them on a
little bit of an angle you might be able to see that that’s not this one you can
see me putting in the other one on the other side so they’re spread apart about
three or four inches that’s just something I thought I might do to just
give it that little extra touch kind of tough to get inside there but it worked
out pretty good all right they asked for the hardest part of the deal at least it
was for me I mean you guys may not see you here on camera but anyways it this
this took the most part I reached down to my fixture clamps right here you know
these things are so handy to have you know having this welding table and with
the fixture clamps it’s just been a huge asset to the shop right here this this
worked out perfectly I was able to clamp it right down to the table a lot of the
works gonna happen right here on this end of the table so I have to drill a
hole in here to start with and again this is the last hole and yes as always
for some reason it’s just giving me a bit of a problem but I ultimately got
through it and then this is going to be the little supports that’s going to
support the dish itself inch and a quarter by eighth inch thick wall square
tube and even though it looks like it’s fairly easy right here I’m making it
look like it’s fairly easy it was a bit of a challenge there’s just so many
angles and so many corners to work with so many radiuses but ultimately you know
I got I got it done just tons of cutting and
getting everything just right to where it’s gonna fit up pretty good
this uh this dish weighs about 50 or 60 pounds and the base plate for this dish
is kind of a lot odd shaped you’ll see here just a minute
there it is so I just wanted to give it some addition support out on the end so
it’s not gonna flex that base plate it’s only 1/8 of an inch thick and it’s kind
of wobbly so this is gonna give us this extra support to make it a little bit
rigid again fix your clamps a clamp to everything down once I knew everything
was gonna fit perfectly and and where it needed to be and just because of the
like the size of the sink I had this thing ran all the way out to the end of
my welding table and you see I’ve got my MIG gun right there and I this was a
real stretch I couldn’t quite rid it you know reach this I have an 8 foot lead on
my on my MIG gun right here and that was stretching it all the way I didn’t want
to move my welding cart you know pull it out with the gas bottles for this just
for this little length right here so you know I just kind of set the MIG gun down
and grab the TIG torch and just finish things up that I couldn’t reach with the
big gun with the TIG torch and you know that worked out pretty good you know
it’s nice to be able to have that versatility everything is on the same
cart and it was just a matter shutting off one switch and turning on another
and everything is good to go so it worked out pretty good
this is just the bracket on that on that part of the mast it’s going to support
that diagonal Pole and then once I got the little frame welded out this is just
a piece of angle iron that I added on either side of the post you give it just
a little bit of extra support it added you know about three more inches to it
one of the very final last thing was cutting out some end caps for the end
the the owner said don’t get too carried away he’s going to do something
different but for now I came up with something fairly quick and I just cut
out some circles right here and this is something that just I went through it in
just a matter a couple of minutes and tried to figure this out just kind of
smoothed out the circles and then just rip some flat pieces of aluminum right
here and I know they’re not perfectly straight but you’re going to get
the idea here in a minute you gotta remember this is just temporary took it
over to the vises just put a little bend on each one of these things I think you
guys might see where I’m going with this and then just tinker all of them a
little bit of an angle and what I’m hoping to do is be able to just slide
these in caps in and just the frictional it will hold them in place so that’s the
idea so I quickly threw those together and just like I was hoping it worked out
perfectly you know I had to assemble this thing right here in my backyard or
next to the shop to be sure everything was going to work the way it’s supposed
to and it worked out pretty good I hope you guys enjoyed this video don’t forget
to check out the website at Jimbo’s garage comm we’ve got some new shirts
over their hats and of course a torch lead holders and also check us out on
Instagram where you get a lot of behind behind-the-scenes action that don’t
quite make it to the channel and also follow us on Facebook thanks for
watching see you guys Simba’s garage

54 thoughts on “Aluminum Boat Mast Build | JIMBO’S GARAGE

  1. cutting aluminium with anything else than a saw is a pain. there are aluminium blades for tablesaws that do an amazing job, not sure about the thickness but you could clearly go multiple passes on that. this would save greatly on sanding time since it leaves a perfectly straight and perpendicular cut. same for the piping, the wood chopsaw can easily function as aluminium cutter 🙂 just keep it safe, meaning eye protection since there are chips flying around and also keep your hands out of the way in case something goes wrong.

  2. Wow lots of aluminum welding ,i have heard aluminum is super hard to weld it. But a professional like you probably a walk in the park

  3. I always enjoy watching your work. Reminds me a lot of my grandfather, who was a master fabricator, but I never had the chance to learn from him.

    Would you ever consider making a video on what you would consider the minimum, best equipment for someone to get for their shop, if they're looking to get into metal work and fabrication? My bad if you already have one; I feel like you'd definitely know was a beginner really needs.

    Keep it up, Jimbo!

  4. Great job, good video. Curious, why not a spool gun? Guess you have your Mig torch, liner, etc, set good enough not to need it. Nice to be able to switch from Mig to Tig when needed.

  5. Great Project! I've noticed that you put the cut off wheel the wrong side on. The little metall ring on the wheel should be on the side of your grinder.

  6. Try running your 50/50 helium mix, it works wonders, i run a 27/73 mix helium argon on my ewm Phoenix 355, find that the puddle wets out nicer and isnt as sluggish as straight argon

  7. تحياتي
    فيديوهاتك أكثر من رائعة
    وشغلك جميل وبإتقان تعلمت منك الكثير ??

  8. Not sure if you read the comments but the next time you are fighting with a hole saw through aluminum you might try juicing things up with wd40 and then while the hole saw is spinning and cutting through the aluminum use a blow gun to blast air through the holes/slots in the side of the hole saw. The compressed air will help clear the chips from the inside out. It can be really messy but getting the chips cleared away from the cutting teeth has helped me when things get gummed up. You wouldn't think that much air can enter from the side of the spinning hole saw but try it. I think you might be surprised. Doug

  9. Like any kind of welding practice makes perfect. Your welds at the end showed improvement from the first ones.
    One thing I noticed though was that you didn’t clean any material before welding. Apparently a quick scrub with a stainless steel brush will clean off the oxidation to allow for a much cleaner weld.

    I was surprised that you could run .035 wire through your mig lead. Where I work when we started to make aluminum vehicle hoods we got a Miller welder with a push pull gun to eliminate having a spool gun. I guess technology has improved over the last 13 or 14 years.

  10. what a guy jimbo ,just an awesome build…………………..all the best ………….dougie

  11. great job like olways ,but you forgot mask, aluminium is a poison end you you should not inhale this shit. Aluminum
    must be welded
    in an argon shield right ?

  12. Another great build video Jim. Step drills are fantastic. I use them daily and they always seem to retain thier sharpness

  13. New to your channel but I've been binge watching your Videos . I've come to a conclusion if Jimbo can't Fabricate it up for you , you Really don't need it ..LOL ..GREAT JOB AS ALWAYS .. :-):-):-)

  14. Looks great! I’ve found that wax or bar soap will help a lot with really any aluminum cutting but definitely hole saws. It keeps them from gumming up which is usually why they cut slow.

    Also you may want to try a trim router for your debur work, not that the noga doesn’t work well but a round over bit will clean up the edge fast and leaves a nice smooth edge that makes it look like you machined it.

  15. Me gusta mucho tu trabajo de mig ,MAG ,aprendo del mejor y el mejor lo eres gracias a like yuor chanel

  16. Jimbo, I kinda cringed when I saw you cutting that miter with the cutting disk and no respirator. All that ally dust going into your lungs, bad joo joo!

  17. Hi Jim
    Why do you think it was difficult to drill the big rounds, do you need specific ally holesaw bits? Or was using the portable drill? Just interested.

  18. I buy carbide tipped blades for my angle grinder. They are extremely dangerous but if your comfortable with your grinder they are amazing for fabricating aluminum!

  19. Wow that was some ugly aluminium welding. Just keep in consideration that when you weld aluminum You push don't pull. I saw a lot of pulling and please fill those craters at the end. They tend to crack at the end of the welds. Fill then grind down the fish eyes. Great videos but your just to new at welding to understand

  20. If you ever work on aluminum again, use diablo blades. They leave a nice clean cut when they're brand new. Also use some sort of lube on the blade.

  21. Those aluminium cutting discs are wax coated to stop it being filled up with aluminium. Wax/lard are really good for cutting aluminium too. The holesaw without having wd40 or any cutting liquid gets stuck from the soft swarf 🙂

  22. Hi Jimbo.
    If you do not mind, I would like to know the type and number of the aluminum gun you are using and where I can buy it.

    My great greetings

  23. Just a tip, you should grind along the edges where you are going to weld and then clean it off with some sort of alcohol so you don't get pores in the weld. Aluminum can be a pain because it's very easy to get discontinuities and they're not always visible from the top.
    Just meant as a friendly tip, keep up the great videos! 🙂

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