How To Make Hairpin Legs From Rebar | Welding 101

How To Make Hairpin Legs From Rebar | Welding 101


hey everyone Chad from ManCrafting and
I just left Tom’s house and this is Tom Mills from GreenShortz DIY
here on YouTube I do a channel that focuses on DIY content within an eye
towards sustainability so rocket stove for example is green
because you use found fuel sticks and twigs versus charcoal or larger logs so
we’re actually doing a collaboration so there’s gonna be two parts to this video
what we’re doing here and what we just did over his house so what we’re doing
today we’re gonna first start by building a jig we’re gonna build some
hairpin legs for a pecan round table he’s got these huge pecan rounds they’re
like two and a half inches thick three inches thick and they’re probably uh uh
it’s on old it’s an old-growth because a 36 inch tree yeah it’s big so we’re
gonna make some table legs you’re working on doing three different tables
we’re gonna work on the first one today right so yeah the three rounds that I
have were from a tree that had to come down for a sewer line installation at my
house and I didn’t want this beautiful majestic piece of wood to go to waste so
I had a lot of it milled into 8-foot links but I had this stump that was
about probably three feet and so I’ve sliced that into three pieces so we’re
gonna make some legs and put them on but then I’ll be making two other sets of
legs with two other youtubers as well so but Chad’s gonna help me out with the
hairpins yeah so the reason I’m helping him with the hairpins
tom has a welder and he could probably do all of this at home on his own but
he’s not used the welder so today we’re gonna get him familiar with how to set
the welder up and how to use it and that way next time when he’s ready to do a
welding project he’ll know kind of what to do yes I have used the welder
although welding I didn’t lay weld with it it was more like spitting metal or
you know shooting wire or you know so I definitely am a rookie right and I might
no means an expert I’m a novice but you know I like to call myself a backyard
welder I I can take two pieces of metal and they will stick together
and you know some people might call me a grinder because you know sometimes you
gotta clean up those welds but actually I’ve gotten a lot better over the last
year well I’d love to get to where you are or at least a little bit closer so I
feel comfortable firing that thing up and getting two pieces of metal to stick
together absolutely well let’s get started so we’ve got our work pieces cut and all
this looks familiar but explain to me what’s going on here
obviously we got the part already cut up the next thing we’re going to do is
we’re going to clean off the edges of the parts so the first thing we need to
do before you weld you want to have clean metal to weld so we’re gonna grind
off the edges of the pipe as well as this little piece of rebar that we’re
using and also the base plate that we’re going to weld to so we want a clean
surface to weld on I have two welders we’re gonna use the Eastwood make one 35
it’s got a flux core in it and since that’s the type of welder you have I
figure that’s the best one for us to use for this video in addition to that you
want to make sure you have a good ground and I actually changed out my welding
clamp from the original and then you based on the metal you’re using you’re
gonna set the MIG to the chart on the inside of the most of them have a chart
on the inside of their door and it’ll tell you what the settings are whether
it’s digital or whether it’s you know with a dial on it either way it’s gonna
be essentially the same types of settings you’re gonna have you no longer
weld times faster speed slower speeds on the wire being fed higher voltage and
yeah that’s I mean that’s pretty much it it’s basically heat gas you know and it
melts to the metal you just have to have a good circuit in order for that to work
so in the case of a wire fed welder the flux core actually generates the gas
correct that protects the the arc correct so I always wear a hat
underneath my welding helmet because works fly and I don’t want to set my
head on fire so I have an extra one for you yeah so the parks gonna go here and here look
about right yeah that’s good our rebar we’re gonna use as a pin and then the
larger piece of fence post here steel that we cut off will Bend the bottom of
the hairpin llegaron that so you put our hot piece hot section in here and the
pin will hold the one edge of the leg will bend it around this way to a a
certain point in this direction so we’ll get that hairpin that’s it so I’m gonna
do the first tack welds and then I’m gonna let you do the actual welding all
right I’m ready I think one thing I want to point out is wear safety glasses
underneath your helmet because sometimes bebés the hot bb’s from welding
especially with flux core are gonna be bouncing off and you don’t want them to
fly underneath the hood and get in your eye
so these pliers they’re welder pliers and they’re designed so that when you
cut the wire it’s the right length so that should be the right amount a lot of
times welders will come with a different style cap on here this is a gas nozzle
and this is a flux core nozzle a lot of times when you get a welder it’s going
to come with the gas nozzle on it and you don’t have this flux core nozzle I
like having this on here when I’m welding with flux core because
especially when you’re a beginner it’s very hard to see where you’re welding
having this on here makes a huge difference it gives you a lot better a
lot better view of the weld put into the back here
after myself for the video essentially you just want to kind of go
in a back-and-forth pattern and you never want the metal you never want the
wire to leave the melted metal so you’ve wanted continuously melting into the to
the feed you want this brightness collies
touching this piece when it does it wants to like grab so get ready to well
yeah I’ll give it a try I’ll set it up and Chad’s let me use his automatic on
and off welding goggles which is amazing so you get to wear my hacklin i’ll
others less people use them still okay they were fun they do so I’m gonna give
this a shot and I’m doing it on the course on the jig which is less
important than the legs however the welds on the legs are gonna
be up under the table so they look horrible
that meant to hold and I think it’s done Jackson would say you know you’re not a
welder you’re a grinding God right so exactly all right did I go too fast
Nene yeah and you’re not actually touching the
okay all right there so you want to make sure it’s pointing right into the corner
okay this part will hold I think that kind of weld over the well can I try
another beat yeah you can go over the top of it yeah that’s fine so before you
wall over it does plate it off any assignment it’s not horrible you just
want to try to make sure you’re getting it right in that 45 and what I do like I
said I rock it back and forth so it scuffing up and down on both pieces and
try to keep that wire about that length as you’re welding so it’s closer which
forms yeah that’s better okay that up and down
motions you’re tired mentally really help so now you can tell both that alone
and it’s actually not I wouldn’t say it’s an ugly world it’s not bad news I
felt I could see it better that time right
it’s a some thing they call it the puddle right yeah once I see where that
puddle is and you can feel like see the wire kind of just going back and forth
in that puddle as its you know it all of a sudden it’s like a light compliance so
much easier let’s do one more can be a little more on that back side that actually looks pretty decent okay so my confidence is already up like
120 percent alright so Chad’s gonna do the piece of rebar on the jig that’s
gonna serve as the pin or bending the leg so I’m just tacking it on to start
with before I start my national feed all right so I did a video called 5/5
for better flex for welding and I haven’t been flexing or welding in a
while so I kind of forgot about it but before I weld
I like to spray this down it’s called anti spatter spray and what Square is
typically kind of messing it there’s a lot of metal Phoebe’s around and if
you’re trying to keep your fart clean and you don’t want those welded to your
surface if you just spray this on just a little bit where you’re going to be
welding that’s going to keep these BBS from actually welding on to the plate
and I’ll do a quick little bead here and then I’ll show you the bb’s how easy
they come on basically well that you see here that’s
nice it’s pretty I’m gonna grind these welds real quick I want to clean them up
and smooth them out a little bit not because we need a pretty well but in
this case we just want it smooth so that when we’re radius ngey rebar that we’re
not fighting the inconsistencies in the weld nice the jig is up the jig is done and
now we just need to heat up the rebar and start forming our legs threes hit a
wire brush on a grinder to take this scale and the rust off of the rebar
here’s a before and then here’s the after I can’t make Chad do all the work
I like your Magneto that’s pretty cool that’s so cool you can hear the train
from Chad’s house listen all right so there’s a different is
really loud it’s amazing so let’s happen in okay oh think we have the critical
emotion inch-and-a-quarter a flat bar steel and we are going to mark it out
into ten inch sections we’re going to cut that and then once we’ve cut that
we’re gonna cut 45s and that’s going to make the base that we’re gonna weld the
rebar to you’re using your twisted sharpie yes what number do you have I
have two sixteen all right when I met Chad for the first time he pulled out
his twisted sharpie actually we were writing we’re writing
and we were doing an exercise for the creator day and I pulled out my sharpie
to write something down and it was like a light went on in his head he was like
oh my gosh twisted sharpie like you know Greg Porter that’s right here in
downtown Lilburn Georgia there are two twisted sharpies well technically I have
three yeah three okay I misplace one that’s like well let me go ahead and get
two there’s one and there’s two more and Chad’s basement yeah this way to find
them is to buy a new one so if you want a twisted sharpie we’ll put a link in
the description below to Greg’s garage and these would go together just like
this they’ll be welded down the center where the 45 cut is and then we’ll weld
the rebar on these ends stops automatically yep sweet there’s a
beast all right let’s roll them off awesome I’m ready that’s a nice I did okay on that one
look at that that is very nice did you impress with your cell phone okay I
could say that smile like do that very well this was the first well for the third world
say there’s an improvement there like everything else on this channel
we’re prototyping I know people have made hairpin legs before but this is
first time we’ve ever done it we have an idea of what to do but the bending you
know we built a little jig so for us it’s prototyping we’re gonna heat up the
middle say three or four inches of this piece of rebar in order to wrap it
around the curvature of that fence post steel that we welded to our jig that
will form the curve bottom of the hairpin leg once they’re bent then we
can adjust the length if we need to make them all the same because we’ll need to
grind a bevel on the on the legs as well since the legs will lean off the that’s
a chance finding the middle here let’s see or that sharpie go don’t you have
one I have one right here it’s twisted yeah imagine that there’s the middle and
then let’s go a couple inches on either side get that close to 5-inch it’s about
right five-and-a-half yeah so a little tighter on the bottom there but I think
that’s okay I like that pointed shape all right so
let’s up that cool I’ll grab it out of them yeah so we got all the legs bent and as
we kind of expected we weren’t going to get them perfect because of the way we
did our Jake but I think they’ll don’t work we’ve allowed a little extra space
at the top of these so that we could trim them off to get them all level I
was expecting perfection but what I do think would work well we doing this
again perhaps is to make sure we had a full like four inches of molten or red
red-hot metal before we started the bend as it worked and so you’re for Joshy
might work better than say a torch here but hey that’s why you prototype right
no art will putting them all in the bandsaw together and we’re cutting with
a 10 degree angle alright now we got the angle on let’s
weld them up gonna be a little more lean it’s good we’ve got our magnet set up
and the baseplate set up so we can repeat this angle on all three legs
alright so what you want to do is start welding at the base of the plate and
then come up here and just tack it on this side and do the same on this side
before you start the full load it sounds good then you see the discoloration on the
backside that means that the well looking good it goes look really close that’s great
yeah we’re actually not closed in it exactly sweet that’ll hold the table that will
hold a beefy table all three are done I think they look really good if you take
a close look at these welds actually let’s get this one in the front cuz this
one I’m gonna grade them a a-plus b-plus yes yeah probably be b-minus b-minus
yeah yeah b-minus it ain’t pretty but it’ll hold so oh yeah functional weld
but I think we did pretty well considering we’ve never done it before
well Tom I appreciate you coming over I think you improved your skills
substantially I’m actually I’m pleased with the results let me give you this
back we’ve been trade in the auto darkening helmet all day there’s your
eye there’s my rookie scooter cool helmet
it’s like an iron iron helmet or scuba diving I don’t know why I’m putting it
on that’s right it’s part of the stick okay so hey I think you did a really
good job I think you’re gonna have a functional table that you’re gonna be
really happy with I really appreciate you coming over and I just wanted to
give you your reward for the day alright does this mean I’m ManCrafting certified
or now mancrafting certified so make sure you go over and watch the rest of
the build on Tom’s channel if you haven’t already if you’re one of my
subscribers if you’re one of Tom’s thanks for coming and sharing this
lesson with us while you’re here though if you’re coming over from my channel
make sure that you subscribe to Chad’s and I’m sure you’ll enjoy the work that you
see happening here on ManCrafting thanks for watching please like comment
or subscribe

26 thoughts on “How To Make Hairpin Legs From Rebar | Welding 101

  1. Sweet collab brother!! I’d love to do some welding. Had a great time hanging out with you and Drew in London. Wish Bernie had been there. Thanks Drew… bwahahaha 😉👊❤️

  2. Thanks for schooling me on the welding process, Chad. And for helping me make the legs. They turned out great! Here's to future collabs!

  3. I think its been about 15 years since I first started welding and I like using my flux core. Doing industrial style work I think it adds to the character of the work for sure. Cool video Chad

  4. Even when my compact bender, the ends are inconsistent. I always cut them long then trim them. As a result, I have hundreds of 1-2" stubs that I need to find a use for. I'd recommend drilling the mounting holes before welding. Good work!

  5. Awesome collaboration between 2 great youtubers! Glad to know I'm not the only grinding god around. :D. What size is your Fablock?

  6. He has improved his welding so quickly. It must be the his teacher??? Great job guys! Cheers, Sean

  7. Hi Chad !!
    It was great to meet you and chat at Makers Central just over a week ago .Loved listening to this vid and it has given some cool ideas.
    KEEP ON TURNING buddy.
    Chris .

  8. awesome video! i enjoyed the collaboration with Tom Mills and look forward to viewing his channel! I always wonder if the spark light from welding can be measured in lumens, and if so, how many lumens is it?

  9. Awesome video! I have been making hairpin leg tables from rounds i have collected from urban trees that have been cut down by the council. I have been buying the the legs but one day want to make them. Love it!

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