This is the second in a series of entries documenting one of our projects as it goes through the design/build process. Although the project is small compared to many of the things we build, the process is much the same.

There’s nothing quite like welded steel for an under structure for the things we build. By using a strong welded steel frame, just about anything we can imagine can be built without worry of structural failure down the road. For this project I raided our scrap bin for short steel off-cuts. What I found determined the length of the various branches more than the original drawing although I had it handy for reference.

using my chop saw I trimmed the ends at appropriate angles, then tacked and welded them securely into place. We use MIG (wire feed, gas shielded) welders in our shop. It sure is a lot easier than the stick welding days of old with a LOT less smoke too. It didn’t take long t put this little frame together - about three quarters of an hour - including interruptions and phone calls. I started with 2” x 2” square tubing and as I worked towards the top I graduated to 1.5” x 1.5” tubing and then 1” x !” tubing. Square tubing is a lot easier to fit and weld than round pipe. After the primary structure was done I bulked out the shape of the lower trunk and the rocks with 1/4” pencil rod.

Stay tuned for part three...

-grampa dan