Windows ~ Part 2 ~ Frames Welded

It has been a while since I started the windows. This has been a big job with hundreds and hundreds of welds and a massive amount of grinding the welds smooth. Working long periods of time with the angle grinder is a problem for me because in the ’70s, I fell off a roof and broke a bone in my right wrist; the bone never healed and is a constant source of pain when I flex my wrist. Because a one-piece bone is in two pieces, my wrist is more and more dislocated as the years go on. So I grind some, take a break then grind some more. I have also been helping Armando with the technical stuff of the shop, such as making sure the roof is the correct pitch, so the windows are taking the time they are taking.

Every window will have two frames; one inside to hold the glass, and a second frame outside to hold the security bars. So far, I have all the frames and security bars welded and ground smooth. A lot of the welds would look even better with some auto body filler (commonly called Bondo), so I am nearing the end of applying and sanding the filler. Here’s what my pile of metal looks like at this point:

A few frames are missing from the photo as they are still on the workbench. You can see that I have taken the design of the curved lines of the cat tails on our front gate and replicated them into the security bars.

My current window-related project is making hinges. I want to be able to open the security bar frames to make window washing and security bar maintenance painting easier. I could have bought some stock steel hinges, but I have seen how thieves easily knock out the hinge pin (even if it is tack welded in place) and gain access to the house. My hinges are a bit beefier. I started with a length of 1/2″ black iron pipe. I spot welded a piece of 1/8″x1″ metal strap iron to the pipe. After cleaning the welds with the angle grinder, I applied two coats of body filler. It looked like this with the first coat of filler being applied:

Then I sanded the assembly smooth with a sandpaper disk on the grinder and cut the 20-foot strip into a whole bunch of 4-inch lengths. I ground the cuts smooth with the grinder. At the bottom of the next photo I show three hinge leaves with a piece of 1/2″ rebar threaded through the leaves. I’ll weld the two ends of the rebar to the leaves, leaving the middle leaf to swing free. Here is the pile of hinge parts:

So that’s where I am with the windows. I hope to get the hinges welded to the frames this week. I still have to fashion a way to lock the security bar frames, but I can see that soon I’ll be cutting holes for the windows in the container walls.

That’s all for now.

4 thoughts on “Windows ~ Part 2 ~ Frames Welded

  1. Hinges are available with non-removeable pins (NRP) which use a set screw, accessible when hinge is open, to lock the hinge pin to the barrel. (Frustrates the hell out of would be burglars!)

  2. Hi Fred, I found your blog the other day and I must say it is quite impressive.
    I just wanted to say wow! can’t wait to see your project finished.

    (I got kind of worried that you had given up posting and was relieved to see your most recent post. ( does that qualify me as a stalker? hope not )) Anyway, greets from Puerto Rico

    • Hi Mariaurora, Thanks for the good words about our project. No, I haven’t given up posting. I really enjoy sitting down and writing these posts. But this rainy season has s.l.o.w.e.d. the project down quite a bit. What I thought would take one month has taken two. It is difficult to get set up for a day’s work when the sky presents a massive downpour. By the time I get tools out of storage in container one and moved to container four I am drenched. Electrical wires are soaked, my feet are muddy, my spirits are dampened, and I am faced with sending Armando home because it is too wet to lay blocks. But the past two days have seen no rain, maybe we are moving toward the dry season. H.o.p.e. springs eternal. Fred

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