Another "how much fun can I have with square tube?" project! Now we're getting closer to present day.
Couldn't post these while doing them because various projects keep overlapping and who knows when one will finish???
Pic#1 Start with a drawing, of course! Dated Feb 2011, idea from 2008. Why does it look like this? I was bored - -
the wall and gate rebuild projects needed an arch, and my initial design in 2006 was the same shape, but wood frame and stucco to match the house!!! BORING!
Pic#2 October 2012 - only a year ago! Where do we start a project like this??? How 'bout at the bottom?
Make a frame, then two more at the joint to the top span - to control the shape in plan.
Stack 'em & tack 'em! Get one perfectly square and flat, then tack the other five together on top of it.
Originally considered building the front face first, then the back, then 2x2x16" spacers between.
Too big for my shop - - needed 4'x18' table to do that comfortably.
Pic#3 Butt welded top & bottom miters first. The joints were gapped about .030, and they look a little high or "cold", but on the test sample, I had full pen (and more!) to the inside of the .083" tube. HH140, .030, C25, V=2, speed 30.
Tried grinding the corners with 3000rpm 7" grinder. I like the 4.5" at "medium" speed better.
Pic#4 Six finished. Inside corners actually look a little better than the picture - it must be the light!
Outside should have been left square to be sanded in line with the upright tubes' outside corner.
Welding table note: I thought that a couple hollow metal doors, 3070x18ga face, would make a useable welding and layout table for this and the entry door. NO. It doesn't. The heat from even a moderate weld "bubbles" the top up 1/8" under it, and pretty soon the whole surface is full of 1/16" hills and valleys. It shows in the last of that stack of frames. If I set them on two boards, #6 wouldn't stick up.
Pic#5 Actually rather important! This shows the arch foundations / planters - (a big project itself!), and the bottom frames aligned with the arch top span longitudinal tubes. Note that the anchor bolts are - as usual - never quite in the corner as perfectly as we want them!
And ... OH CRAP ... ... the length is 5" longer than the drawing!!! So ...