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Welding

The metal pieces for the Eco-Headboard are welded.

From "Freeform Furniture"
episode DFFF-108

In this third segment host Amy Devers makes miter cuts into the steel u-channel and cuts steel tubing using a metal chop saw. She then cuts screw holes into the metal parts, and then welds the mitered u-channels together and leg parts together.

Host Amy Devers welds the pieces for the...

Eco Headboard.

Materials:

Clear vinyl
3/4" pre-finished maple plywood
1/2" unfinished plywood
T-nuts
2" foam
Bonded batting
Muslin
Staples
Steel U-channel
Recycled T-shirts
1-1/2" stainless steel tube
1/8" round-over bit
Forstner bit
Wax pencil
Ruler
Heavy-duty thread
Spray adhesive
Clean rags
Spray paint
Tape measure
Welding gloves
Ear protection
Safety glasses
Face shield
Cutting fluid
Welding jacket
Welding mask
Filler rod

Tools:

Staple gun
Laminate trimmer
Clamps
Awl
Drill
Drill press
Hammer
Shears
Razor knife
Sewing machine
Respirator
Chop saw
Ratchet
TIG welder
Grinder
Hand sander

Figure A

Figure B

Figure C

Figure D

Figure E

Figure F

Welding

A steel u-channel (figure A) is used for the frame. The corners will be mitered and welded with holes drilled in the edge to attach to the headboard.
The legs are made out of 1-1/2" square steel tube. This is available from an industrial metal supplier for about $2 a foot. The leg is made of two different parts that are cut on an angle and welded together (figure B).
Use a special chop saw blade (abrasive cut off wheel) and starting with the steel channel, cut the top piece of the frame about 2" oversized.
Cut the two sides of the frame oversized as well.
Set the saw at 45-degree angle and make miter cuts on either end of the top channel and one miter cut on each end of the side pieces.
Cut the 1-1/2" tubing into four pieces.
Reset the saw at a 5-degree angle and cut one end of each piece. When these go together, they will create a 10-degree angle (figure C).
Take the cut parts over to the drill press and drill six holes in each of the channel frames for the screws that will be used to attach the entire headboard to the bed.
Use a drop of lubricant before drilling each hole in the metal (figure D). This prevents the metal from getting too hot and damaging the drill bit.
Drill holes in the legs for the bolts that hold the legs onto the headboard.
Tip: If you don't have a welder of your own, take your pre-cut metal to your local trailer hitch installer. They are used to doing small jobs and they can be pretty reasonable.
Clamp two parts of the channel frame to the welding table using a magnetic welding clamp with a right angle. The clamp has a magnet to secure the work piece to the table.
Make sure the miter is tight and then on the inside of the miter, weld the two pieces together (figure E). Repeat the process on the other miter.
Welding the legs is next. Each leg is made up of two pieces so that when welded together, they will form a slight 10-degree angle.
Note: The legs were designed with an angle so they can attach flush to the bed frame and then slope back 5" to allow for reclining in bed.
With leg parts clamped to the table, weld one side of the joint, flip it over, and weld the other side. Repeat this process on the other leg.
With the grinder, grind the welds flat and sand them smooth using a hand sander (figure F).