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If you've read my post about powder coating, which you probably haven't, since its not done, then you know that in order to successfully powder coat something, it must be properly prepped, and in almost every case, the part you want to coat must be stripped down to bare metal. The most effective, fun, exciting, dangerous, unhealthy, and generally guaranteed slaphappy way of doing this is by sandblasting.
sandblast
[sand-blast, -blahst]
noun
1. a blast of air or steam laden with sand, used to clean, grind,cut, or decorate hard surfaces, as of glass, stone, or metal. 2. the apparatus used to apply such a blast. verb (used with object), verb (used without object) 3. to clean, smooth, etc., with a sandblast. So basically, sandblasting is sand mixed in with air blasted at high speeds. The sand does the same thing sand paper would do, minus the paper. Alright, so my description isn't the most detailed in the world, but most of you know
enough about what sandblasting does to not need a description or explanation. Plus you're already on the internet so you shouldn't have much of a problem finding more information about it, right?
My buddy Jim down at the shop keeps saying Media Blast!, what the heck is he talking about??
Glad you asked. Sandblasting is probably the most commonly used term, but did you know that people also call it media blasting, abrasive blasting, grit blasting, shot blasting and probably a bunch of other stuff too? Personally, I call it abrasive blasting, since I never use sand, and will call it that from here on out. The term "sandblasting" was most likely coined because the guy or girl who invented the process probably used sand. Honestly, I'm just taking a guess here. I'm too lazy to open a new tab in my browser and look up any real facts to back that statement up; although, you have to admit, it sounds good, doesn't it? Oh, and if i'm wrong, consider this an apology. Nowadays there are many choices of synthetic, natural, unnatural, semisynthetic, simi-natural, simi-unnatural, unnaturally synthetic and synthetically simi-natural medias to choose from, and most, if not all of these, are far superior and safer to use than normal sand. The main issue with regular sand is that the dust created from sand contains a high amount of silica, which inhaled over a period of time will cause a disease called silicosis. Silicosis is something you DON'T want to have. Trust me, or look it up if you don't believe me, or die if you don't want to look it up, but just remember that I gave you options. Abrasive blasting can be used for all sorts fanciness from heavy duty stuff like blasting rust off of aircraft carriers to doing delicate work like etching things or even giving your jeans that "worn out" look that everyone loves. But just in case you were wondering, my main goal for blasting will be preparing miscellaneous parts for a fresh coat of paint or powder.
which makes a lovely mess. Another benefit is that you can re-use the media over and over until it has reached its end of life. I'm not saying that you can't re-use media if you don't use a blasting cabinet, it's just a shit ton easier to reclaim the stuff when its contained. An obvious disadvantage is that the size of your work is restricted by the physical size of your blasting cabinet, so no matter how hard you try, that 4x5 object won't fit into your 3x4 cabinet. That being said said, I built my cabinet a little bit bigger than the biggest project on my horizon: the rebuild of my 1999 Suzuki DR 350 that was submerged in salt water for hours and hours during a hurricane that flooded my city, including my garage
Save yourselves!
I'm not a genius, nor am I very inventive. I am just a guy motivated by the simple needs to blast my motorcycle frame down to bare metal. The easy route could have easily been to purchase a beautiful, professionally built, long lasting, warranted abrasive blasting cabinet by xyz inc, but what fun would that be? Also, I come from a long line of do it yourselves and I would be doing nothing more than shaming my forebears by taking the road most traveled and purchasing a shiny, brand new abrasive blasting cabinet. Ok, so maybe it helps that the same size cabinet as the one I'm building would have set me back almost 10 times the amount that I paid to make mine...
Disclaim-errrrr?
As I've said before in my post about powder coating, let me warn you now that this is by no means a tutorial, how-to, or any other kind of guide meant to be duplicated or copied, simply due to the fact that this is the first time I've done this myself, and honestly I'm simply not the type of guy you want to follow if the ship we are on is sinking. Buuuuttt...if you are keen enough, you should be able to get the gist of things and might actually be able to successfully follow my flab jab and clamor without leaving this earth. But seriously, don't get pissed at me when you realize that I didn't mention dimensions, or any other "important details". I just create this junk as I go.
Suzuki DR 350 frame and is a good size bigger than your standard $300-600 blasting cabinet.
The base
While I was in the process of planning out my design for a base, I happened to glance over at a sturdy mobile bench that I built a while back. This thing would make a solid base for my blasting cabinet and it just so happens that the base is 2'x4' which is perfect. Of course the downfall now is that I have to build another bench... Oh well, at least that gives me another article to bore you with in the future. Heres what the bench looked like after a few modifications made so I can successfully "mount" the cabinet to it.
My design is pretty basic and some of you probably know a better way of doing this, but this concept came to mind first. What I did here was subtract the thickness of my plywood (1/2") from the outer edges of the base and screwed in 2x2s around the base using those measurements. This design will not only allow my cabinet something to screw into, but it will also allow the cabinet to be flush with the base. Another great feature is that when my cabinet is done, I will be able to unscrew it easily from the base and transfer it to another base (with a media chute) later. Whatever, It worked... Like I just mentioned, my current design doesn't have the media "chute" that most blasting cabinets have which allows for the media to slide down a chute that resembles an upside down pyramid, although I do plan on adding that real soon, so check back! A close up of the wood work shows how I built the extension of my bench to convert it into a base for my blasting cabinet. The distance from the 2x2 and the base edge is the exact thickness of the plywood being used. A time saving tip for this step would be to use scrap plywood to measure that
distance instead of actually measuring it out. Oh, and don't forget to pre-drill any holes because the 2x2s split easily if you don't!
If you guessed 4' x 18" than you win! If you guessed anything else, I win! After the walls and ceiling come together, this thing really starts to look like a blasting cabinet, kind of. NOTE: This is where you start to get excited and start rushing your cuts. I'm not one to say slow down and pay attention, after all, I am a measure once cut twice type of guy, but these steps require a pretty good amount of accuracy if you want your cabinet to look decent. Don't worry though, your favorite sealant can seal any ungodly cracks if you aren't that steady with a saw. I'm not.
jig saw for this, but I used a circular saw because I am impatient and awesome.
You can see some light shining through due to my lack of circular saw skills, but nothing that a little sealant wont fix!
just shatters and is too easy to break. This type of glass isn't good for this project. Looking further in the pile I came across a few sheets of tempered glass which would have been the perfect choice if the size was right, but once tempered glass is tempered, it can't be cut without special equipment. My diamond in the rough was a sheet of "safety glass". Safety glass is a sheet of plastic (the "membrane") with sheets of glass glued to each side, like a sandwich. Its used in places where the risk of cutting yourself is pretty high, like in old automobile windows, or in glass doors. When broken, the glass just cracks and the plastic membrane in between would prevent it from actually coming apart into nice, sharp pieces, thus keeping your throat out of harms way. Seems perfect for my project! Now I just need to cut it to the proper size...
So now that I had the tool, the instructions say to score a perfectly straight line across a sheet of glass using the supplied cutting tool, then either tap the glass with the ball on the end of the tool or lift and drop the glass from a short distance while half is on your work area and the other half you want to break of is not. The piece should cleanly break off if done properly.
Using a mixture of the ball and a bit of the drop method I could clearly see that the glass was perfectly broken on both sides. But now the the plastic in the glass was preventing it from separating and the break in the glass is so thin that a piece of hair couldn't fit between. What the hell do I do now? The not so obvious second step that I mentioned above was fire! (There is also a special chemical you can buy that is designed for dissolving the plastic membrane, but I jump at any chance I can to use fire!) FUN FILLED FACTOID: A little bit of rubbing alcohol taken from ye ole medicine cabinet works wonders for cleaning out cuts, but did you know that it also works wonders separating pieces of safety glass? Yep! It melts right through that plastic membrane like butter! DEATH ALERT: I suggest sweeping up any piles of sawdust before continuing. Also, if you die, I am sorry. Lets continue, shall we? Working one side at a time, pour the rubbing alcohol over the glass and set it ablaze. This will start to melt the plastic membrane. Pull your glass to the edge of your work area and let one half dangle off a bit so gravity helps with the separation, but watch out for the fire, it will burn you up if you allow it to. Also, don't let gravity get the best of you: make sure you hold the piece of glass dangling over the edge! Flip the glass over and do the same thing again, but this time be careful because it will separate on you, and having a decent size piece of flaming glass come apart in your hands can be intimidating at best.
Repeat the whole process for the width (or length, depending on what you cut first,) and you should end up with the piece of glass that you need. TIME SAVING TIP: Skip this entire section and go out and get a piece of glass cut for like seven dollars.
Test fit
Now would probably be a good idea to see if the DR frame fits, because if it didn't fit now, I would chainsaw this thing to death. Needless to say, everything is 400 times better than what I would have expected.
The door is probably the most "complex" part of this whole build since it includes parts other than wood. This is what I used for my door, all of it came from The Home Depot: 1. Piano hinge (one long hinge) 2. "Surface mount" latches 3. Silicone gasket (was the only gasket material that said it was rated to seal out smoke) The dimensions for the door are simple. Stand on the side of your cabinet, whichever side you cut the entry on, and measure the outside perimeter. Make that cut, and you have yourself a door. If everything works well, it should look like this:
Now we need to get the hinge on this thing. I attached my hinge to the inside of the door like so:
The next part would have been much easier with two people but I didn't have any help at the time so don't be discouraged if you don't have anyone to help either! Now the door must be mounted to the cabinet. The other part of the hinge will be mounted to the back wall. Once mounted, the door should open and close freely. If it doesn't, you screwed up.
Latches
Let me first start off by saying that I plan on using a better method of latching my door, but I couldn't think of anything else at the time. What I used were "surface mount" latches. These were the only latches I could find that allowed my door to latch closed properly, although I really didn't look very hard. The satin nickel finish really classes everything up...
My current door design along with my current latching system didn't work out
of the box... Like I said in the beginning, I just build I as go. A simple modification (scrap wood) allowed my latches to latch.
Here is the bottom latch. I plan on adding one more in between the two... Or just re-do the entire latch system itself...
The gloves
Now the fun part! Its time to cut out the holes where the gloves will go. Instead of making my glove mounts out of PVC like a few people on the net, I
just went ahead and purchased them from the same place I bought my gloves. The gloves and the glove mounts were by far the most expensive thing, but the quality really does makes up for it. The last thing most people want to do is to blast their hands off. Cutting out the holes was pretty straight forward, and there wasn't much room for error. I drew a line across the cabinet about 3 inches up from the bottom of the base which gave me horizontal evenness across the cabinet for my gloves. Then I just marked where I wanted them to go and cut away. It came out just fine and feels pretty damn "ergonomic" to me... Check the picture out in case you don't understand anything I am saying. Don't feel bad, after re-reading it, I don't.
After cutting all 4 holes, the next step was to screw in the glove mounts that I purchased. Needs no explanation, so I wont be explaining.
After all 4 glove mounts were installed, I installed the gloves by slipping them onto the mounts and tightening a clamp around them. The clamps came included with the glove mount kits that I purchased from tptools.com.
Here we can see all of the gloves installed. This setup gives me fairly comfortable access to pretty much every inch of the cabinet.
collector, but this should be enough to get you started. Also in the works is redesigning the base for easier media collection because right now it just piles up and has to be scooped or vacuumed out, which slows me down. Stay tuned for updates on that.
The fine folks at US Minerals were kind enough to give me 200lbs of their product for free, which, unfortunately to them worked out in my favor because the "Coarse" media didn't work regardless which nozzle I used. I ended up going back and payed for a couple of hundred pounds of "Fine" media, which is working out very well. I was kind of bummed that the prices seemed to be the exact same as anywhere else. They were producing the stuff on the spot which seemed neat, and the entire property, including the parking lot, was literally covered in this stuff. It was everywhere. Oh well... It's still very convenient and cool that its produced here...I guess.
Here is a video of me, blasting the bars with "Fine" black magnum coal slag. http://www.youtube.com/watch?feature=player_embedded&v=9IPDYlkd0Ac Here is what the bars look like when I finished. I'd say that we have ourselves a working cabinet.
vacuum gate works great) to empty spent media. 5 gallon bucket below, open the gate, viola! got rid of the bad stuff. Harbor Freight sells the gloves cheap. Just search fro the blast cabinet, download the operating manual and order the gloves and mounts from the replacement parts list. Ive recently added a vacuum port and redesigned the bottom of the cabinet to drain into a bucket. I will update the blog to show it in action. Im happy with the results and its a lot easier to work with If you line the cabinet with rubber roofing membrane it will last alot longer. Although it will be dark inside since the rubber is usually black. Great article and idea. You presented it very well.