ruffles' handbuilt diy contest monstrosity -- DONE! (Whew!)

your man pants must have more space for swinging pendulums as that’s bloody quick. Then again, B&D probably didn’t envisage some muppet cutting through 1x2in alu bar with their jigsaw :slight_smile:

Mentioning “man shirt” and “man pants” from a user whose name is “ruffles” just seems a little odd :)… Sorry, I couldn’t help it :)!!

I know it’s supposed to be portable but this is shaping up to be a shoulder fired fugly monster. Keep it going, I love it! :open_mouth:

That’s for when the flux capacitor goes critical — duh!

Anyway, updated pics+chatter in post 3… enjoy.

Fair dinkum. I’m sure OL did not realize what he would create when he was in the bowels off his shed smoking whatever dreaming up this comp. You guys doing the hand tools build all have one thing happening to you that is common through all the builds. Your all going to have arms on you like Arnold Schwarzenegger. Maybe when this comps over we could have another comp to see who has the biggest biceps off you all. Keep it up guys. I don’t think there will be any machine builds happening as you have put us all to shame.

Wow! That threaded aluminum with the Dewalt battery shown for size reference really put it's size into perspective! Wow! Are you sure this thing will really be portable? Maybe with a dolly to transport it?

-Garry

Post three updated with lots of pics and rambling commentary.

Hope you like it!

Wow! You’ve come along pretty well. I’m a little surprised about that white wall shot… the beam looks not bad for a “tower of power” (you are from CA, right :laughing:!!

Ruffles,

I don’t know if the broken hand tap is still bothering you (or if anyone reading this on the “interweb” cares).

I’ve run into similar situations before doing work on cars and completely agree drilling it out is a “no go.” The metal is harder than the vast majority of drill bits. That extreme hardness also makes it brittle so I have had good luck breaking it up with a punch and a ball peen hammer then extracting the pieces.

The traditional way of removing broken taps from aluminum and aluminium is to dissolve them out with nitric acid. The strength of the acid can be important. If it is too strong it passivates the tap material and they won’t dissolve. Too weak and the tap wont dissolve. A little googling should provide some help.

Other people report good results using alum (sold in grocery stores for pickling vegetables). You simmer the part for several hours in an alum solution. Also works for taps in copper/brass that nitric acid will dissolve.

Well done ruffles. I need a new light in my shed. We enjoyed every minute off your build as much as you enjoyed building it. Thanks.

Congrats on a job well done.

-Garry

Congratulations!
Nice build!

Great build, ruffles! That’s a monster, and will make a nice work light. Good job adjusting to adversity along the way. :beer:

Nice build! 8)

Okay, maybe more than one, but just a note that I got a chance to light up the backyard last night.

It was too late and I was too tired to set up for beamshots, but this thing is super floody. (The 60 degree lenses may have had something to do with that!) I’m guessing something like 1000-1500 lumens, but I can’t be sure.

Thanks again, O-L, and mega-congrats to all participants. I’m thoroughly awestruck by the skill and creativity shown here.

This video clip accurately describes my role in this contest, I think:

Awesome work!

wow. I like your style. It looks like something I would build. Only better.

that’s some pretty crazy work there! The copper bezel was a really neat touch too. The only problem I can see now is explaining to people why you have a buff right arm and a skinny left arm; “no, really, it’s from sawing a lot of solid aluminium for a flashlight contest”!

Tower of power. Nice call ohaya, this a really blaring light. This hobby is great because there are so many different components that force you to grow in new ways. I’ve learned more about more different topics since joining the forum than in many years previously. Whether bigger and better or smaller and better I hope you keep modding and get better and better. Great big build Ruffles!