There is no need to spend a huge amount of money on tools. We are huge fans of finding how to videos on youtube and found this gem the other day. DIY welding at it's best. Also check out more detail on this build over at instructables.com
Damn is it cool to see something that leaves your jaw flapping in the wind. This Dia De La Muertos mask by Shane Martin is a true work of art. The precision in the design of found objects alludes to a very analytical mind that we are looking forward to seeing plenty more work from. Check out Shane Martin's work on Deviant Art
Dia De La Muertos Sugar Skull by Brian Martin made out of emtal
We were guessing with Jesse James bike build off on Discovery Channel that he would be working on a new show for the channel and our theories were proven correct. Discovery is a great channel overall, but we have always wondered why they kept the American Chopper show on for so long, as the show is more about high paid advertising and family drama rather than about motorcycles or custom builds. We completely rationalize with the idea that the corporate advertising pays for the channel and gives them the ability to produce more shows, but to what detriment? The family squabbles made a mockery of the Teutels and it became just another soap opera, same as ESPN. Not that their builds were something we enjoy or would ever ride, but imagine yourself as a teenager and thinking on a career path. By being able to see a machinist, builder, fabricator, mechanic etc. as a viable career choice, they are missing a huge opportunity to truly grow their market share. Mike Rowe's Dirty Jobs portrays all sorts of tough jobs that are being done and are providing an honest living that aren't cubicle driven.
America has forgotten how we got started and what made us great. Many have forgotten what it is like to fix the random item that breaks at the home or how to do an oil change. College is not always the solution or striving for the proverbial white collar job. Trade careers are continuing to diminish as we are losing our industrial might which is sad. Hopefully with Jesse James new show, Discovery will once again focus on craftsmanship instead of drama. The same as most should focus on his amazing skill set compared to his personal life.
Granted many folks are voyeurs and live vicariously through others, so we ask this. Instead of watching life go by, become an entrenched part of it. If ya don't know how to dial in four carburetors, learn. If ya can't bend sheet metal or weld, go to your local community college and take some classes. Life is too damn short so go out and make something happen that you can call your own.
Leave a legacy and something to be remembered by, take the high road and make it work.
Jesse James TIG Welding - Photo from Cyril Huze Blog
Cyril Huze posted an interview with Jesse about the build off coming up
next week with the Teutels and you can read it below or link back over
to the original article.
Jesse James, Paul Junior and Senior duel in the ultimate TV build-off on the Discovery Channel and you are about to decide who is the best builder. In advance of the 2-day TV event (Episode “Chopper Finale” December 5 at 9 pm when the 3 customs will be revealed, Episode “Chopper Live” December 6 at 9 pm to vote and see the winner), Jesse James took some time to answer my questions…ramping-up the smack talk against the Teutuls… A couple of revelations, too.
Cyril. Although I can’t show pictures of your bike before Monday’s and Tuesday’s episodes, can you explain to my readers your approach for this build-off, what type of bike did you build. Jesse. I just wanted to build a bike purely for myself. I wanted a style and materials that “I” want. At the end of the day I’m keeping this fucker, so I might as well do something that I will dig.
Cyril. How much help did you get? Jesse. Ha! The only real help I had was unloading the truck of raw material coming in the door of the shop. Really I had Bacon with me the whole time helping run parts and this and that. Which I could not have done without him. Jeff Decker and Cole Foster also stopped by for a couple days to help out. It was so great doing this with my friends.
Jesse James getting proper measurements for ride comfort - Photo from Cyril Huze Blog
Cyril. Do you think that the bikes you build today are very different from the ones you were known for years ago? Which way? Jesse. I think this is a big step out of my comfort zone. It’s leaner and meaner and uses a lot of materials and skills that I have been afraid to work with in the past. Mostly because I wasn’t that good at working with them. I think I needed to push myself on this build. Just to prove that I can do what I do from my new shop at home. 17 years of having the power and resources of West Coast Choppers in my back pocket. Now that is all gone. Time for me to prove that I was really the driving force behind all of it. I have to admit I was a bit nervous hanging it all out there on my own.
Cyril. Do you have a personal and/or professional gripe with those 2? Jesse. I doubt if I would piss on either one if they were on fire :- )
Cyril. Would you hire any of them in your Austin shop? To do what? Jesse. Absolutely Not. I have 19 y.o. kids at my Austin Speed Shop that would work circles around any one of them…
Cyril. Your definition of a great custom motorcycle? Jesse. Frame, Motor, Trans, Small tank, Brakes and lots of Love. Minus a reference point.
Wooden mold for a custom tank by Jesse James - Photo from Cyril Huze Blog
Cyril. Do you think it’s possible that one of them, or both, surprise you with a bike your really like?
Jesse. I really wish and hope one of them would build something Bad Ass. Something I would tip my hat too. Sadly I think we all know it will just be more of the same. They really want to beat me so they will be emptying the parts room. Welding as many wings, and scoops, and fins as possible.
Cyril. It seems that it will be a popularity contest more than anything else. Can a bad boy get more votes than 2 “family men”?
Jesse. Yeah, Jr. started trying to mooch votes and couple weeks ago. Pretty Lame. I have an idea! How about we show people the bikes first, then ask them to vote.
Cyril. There are ultimately 2 possibilities for you. Tell me why you will win? Why you could lose?
Jesse. I think there are actually 3. I think this is my chance to remind people what I really do. I think there is a large amount of people that think I’m famous just because I married a Hollywood actress. I really hope to show people that since Monster Garage ended that I have done nothing but devote myself to my skills. I really think that I am 100 times better now. I hope people see this and I inspires them to follow there passion like I have.
Cyril. Does the result really matter to you?
Jesse. I’d love to win, but if I don’t it will not change my feelings about my bike, not even 1%. It’s a Bad Motherfucker, and I love it!
Cyril. With the result of this competition, is your return on the Discovery Channel with your own show on the line?
Jesse. We start filming an All New Series in January for the Discovery Channel.
Cyril. What kind of TV show you prefer to have? Building? Teaching? Entertaining?
Jesse. Bigger Better Monster Garage, Time to Put Discovery on the map again and cut a new Groove in Television.
Not quite sure how we exactly found out about Brown Dog Welding, but maybe it found us. Seems to be the way thee ol' inner web starts to find similarities. Maybe our google query was "cool metal fabrication" or it could have been "way too talented metal workers" but we happened to find Josh over at Brown Dog Welding and have been hooked on his cool projects ever since.
After a few emails back and forth, we asked Josh if we would be into a quick interview showcasing his work and ideas. He happily obliged, so here ya go folks, an interview with an amazing fabricator, artisan and all around good dude.
To take a page out of QBall's vernacular, "Long may you fabricate!" Thanks again Josh, we dig your fast response, interesting approach to applied metal craft and all around creativity in what might be scrap metal to the masses.
I'm originally from just south of Grand Rapids, Michigan....a little
town called Middleville. I'vebeen in Detroit for the last 10
years, and in between was a year and a half stint in SoCal.
What makes you stop and think "I could do that and do it better"
I remember having one of the welding instructors at Chrysler's tech
center tell me that it was way too difficult to make money in
art.....the time, the traveling to shows....it just wasn't worth it. That was never the route I wanted to take though. With the
internet I can reach an audience larger than the "craft" circuit
will ever touch. I looked at the sites that existed for metal art,
and most were pretty poorly done. Blurry pictures, generic web
templates, boring descriptions, and a handful of items that were
basically from a blueprint made over and over and over again. So I
spent a little more money and time up front to create a better
presentation. From the site to the pictures to the packaging, I
wanted it to be slick. And really the same goes for the art. There are a lot of guys out
there that do scrap metal "sculpting." There aren't a lot of guys
that take the time to make it look right, proportional...a polished
finished product. Kinda like there are rat rod guys who build cool
rides with character AND craftsmanship versus guys who use it as an
excuse to be lazy and do shit work.
The Devil is in the details, holy shit talk about technique
Only TIG Welding can look this good
On the other side, you've got a bunch of "fine" artists who come up
with a metal concept, think they can grab a mig gun and make it
happen. I was at the DIA(Detroit Institute of Arts) two summers ago
and there were several pieces that fit into this category. I can't
paint, and even if I've got a brilliant idea for a painting I'm not
gonna pick up a brush, it would be a mockery to the genre. But for
some reason these guys think piss poor metal work isn't gonna
detract from their "metal art". Welding has always been first for
me. The art has always been an extension of that.
And with the welding....I showed an aptitude for it right off the
bat, and just kept challenging myself to get better, more
consistent, proficient in different techniques. I was surrounded
by experienced guys I could learn from, and they pushed and
encouraged me. I'm not a "with hard work you can do anything" kind
of person. Drives me nuts, because it's such a common cliche we
hear every day. But you gotta have talent, passion, AND a work
ethic. 1 or 2 out of 3, and you'll be alright. Just the work
ethic, and you'll reach your potential. Put all three
together, and the sky is the limit. I'd like to think that's where
I am, and I keep pushing myslf.
How did ya get into welding or thinking that glowing hot metal is
better than splinters and saw dust?
Dumb luck. Long story short, despite growing up with a dad and
grandfather who were both gifted craftsmen, I had no desire to get
my hands dirty. I didn't take so much as a shop class growing up.
After breezing through high school, I went to college and quickly
realized that wasn't for me. What I did get out of college were
some great friends and my future wife, Darla. Her dad was a
millwright at Chrysler, and he helped me apply there. Once I got my
foot in the door I took the skilled trades test. Shortly after that
was a layoff from Mopar, then a move to SoCal, the wedding, and a
move back to Michigan. I got the call to begin my millwright
apprenticeship at Chrysler in the fall of 2002. At some point
during the first few weeks of training at the Chrysler/UAW tech
center, one of the instructors snuck us out back and fired up a
generator. He handed me a stinger with a 6010 electrode in it, and
once the arc was struck I was hooked. I set myself on fire, too. Was the first time, definitely not the last.
5 Window Coupe Engine Details
5 Window Coupe
If not working in metal, what other area do you think you could
excel?
I'd pry start a cult and prey on the naivety of youth. Or maybe
I'd be a concert pianist.
TIG Strings are just purdy
Cult conviction is required for all the details on these builds
How often on a job site do you get to be creative or weld your
way out of a corner?
Working in prototype, every day.
Does production work fuel your creative work?
Nope. I don't do production work, and never have. I've got a very
limited attention span, I'd never make it! My current full time
gig is at General Dynamics working in their prototype shop, and I
love it. Always something different.
Matchless G50 Race Bike
Alien Robot and Dog
If you didn't have any size limits or worry on shipping what kind
of sculptures would you build?
I've thought about doing some large scale stuff, but that would
require taking my time and planning! I'm not much for either. Maybe one of these days...
Get tech with the readers, what is your current shop setup for
welding, cutting and machining?
In my personal shop I've got a Miller DVI 2 mig machine, a Miller
Dynasty 200DX for tig/stick and a Hypertherm Powermax 30 plasma
cutter. I've also got a oxy/acy setup, drill press, band saw, ect.
Basic stuff as far as that goes, I don't do any machining. The
Dynasty is definitely the shop workhorse.
Recycled Die Grinder Sculpture
Do ya think good machines are overkill with too many features or
should everyone learn to gas weld at first to understand puddle
flow?
As an apprentice taking the intro to welding course at Macomb CC, we
did gas welding... and I really haven't done much of it since.
It's cool because it's traditional, and there can be some benefits
using it on chromoly and even aluminum, but tig welding really just
blows it away as far as versatility, precision, and ease of
operation. Learning to weld with tig as opposed to gas isn't much
of a negative in my eyes.
And the new inverter machines are super sick. I've got the 200dx at
home, and at work we've got a shop full of Dynasty 350s and a 700. Maybe you don't need all the features, and personally I'm not much
of a "geek" when it comes to studying the waveforms and whatnot, but
a few of them are handy doing fab work you'd do in your garage. The
ability to crank up the pulses per second on stainless steel really
helps control warping and increases corrosion resistance. The
frequency and balance adjustment in A/C can help you dial in a bead
for welding aluminum, and on the 350/700 machines you can adjust it
even farther for cleaning or penetration with separate wave
controls.
The flip side of that is that folks (usually, but not always,
beginners) often get too caught up in the settings and features. I
get asked all the time "what settings are you using? What tungsten?
What cup? how many amps?" ...like if you set it all up the same,
it's just gonna work like magic. In reality, it's nice to have the
ability to fine tune a machine for a particular joint, position, or
material, but you've still gotta have the skills to pay the bills. Half the time I sit down at a machine in the shop I don't even look
at how it's set up, I just turn it on and go. And if you've got an
older transformer machine, there's nothing wrong with that either.
I learned on a monster Miller Syncrowave, and I've seen some
beautiful work done with ancient Linde Heliarc machines too.
Nuts, Bolts and Bulldogs
Metal Head Elephants
Material prep and cleanliness, however, can't be overstated. Cleanliness is godliness when it comes to welding.
If you're learning, do yourself a favor and take a community college
class. Preferably one that does, at the very least, some type of
destructive testing. I've pissed off a lot of self taught DIY guys
in the past by saying this, but you don't know what you don't
know. So much goes into make a weld strong.
What music do ya dig listenin' to in the shop?
Chopin, Rachmaninoff, or even some old school Ennio Morricone
scores. They make you feel ten foot tall and bullet proof. If I
listen to Tool, RATM, or Nirvana I end up losing my patience,
cursing and throwing junk everywhere. Daft Punk, Justice, or
Deadmau5 you can weld to...but no rap or hip hop. Totally throws my
rhythm off.
A crazy idea struck us earlier this summer. We figured that building a new setup for all the shows we do at motorcycle, hot rod and music events would be a good idea. Of course this was all on the fly and didn't even really think on drawing up a fully fleshed out idea as our clever concept entailed obtaining all recycled material or at least mostly refurbished steel and wood.
Several sketches and quite a few beers later we posted a note up on the local craigslist looking for scrap steel. Within a few days we got an email from a couple about an hour away that had an old steel staircase that needed tearing down and offered the steel for free if we hauled it away. How could we pass up on the opportunity to spend ten hours and over 30 cut off wheels cutting down an entire staircase? Yes, we are gluttons for punishment as this was all accomplished in close to a hundred degree heat and southern humidity, our normal operating temperature.
With all the steel finally at the shop we could take measurements and really see what we had to work with. The beams were our main interest along with the pipe as that would be our main structural support for the floor deck and poles to support the roof. The steel was under a huge amount of tension with the step supports that were welded on as they had begin to flex over the forty years that the stairs had been in use. As we we were cutting off the support brackets the steel was snapping back into its original shape. If that won't rattle your nerves handling big beams, not sure what else will, as you can guess this stuff isn't light.
Knowing how big our projects can get I cast out a blank series of text messages for "volunteers". One lone ranger opted to show up and help and we thank none other than Jukebox Hank for rolling down for three days for some sweat equity. Without his help in getting all the grinding and metal prep done on the box frame, we truly would have been up shits creek. The setup of the beams should have been a three man job to line things up and weld in the brackets to hold the corner bolts but we did it with two and several cinder blocks. The beams now lock into place with a series of four large bolts and the supports of the crossmember wood and steel pipe hold it all together so its easy to assemble and disassemble. In all actuality, one person can build the entire platform now without any other help as I had to do close to seven times to really dial in the construction of it on the fly.
One of the last pieces that we needed was refurbished floor planks. Luckily we have a Habitat for Humanity a couple of miles down the road and was able to purchase a stack of eighteen 2 x 6 x 10's in a variety of lengths. With the planks, our floor could now be completed and we cut those all to length and placed them in a specific alignment to lock the wood in tight and employed a few shims to really tighten it up.
Our plan is that now with a solid floor we can also use this for indoor shows as a bike platform or a raised deck for a variety of setups. We dig having an old country store feel as it matches the vibe we are going for. This stage has been truly labor intensive to build, but it solidifies exactly what we are doing and doesn't look like a lame cookie cutter tent at outdoor festivals. Add in our wrench knives flags and a variety of roof options and we are set for just about any damn show we need to do. 2012, here we come!
Total Cost, just under $180 bucks with excess cut off wheels, bolts, welding wire, etc. etc. Who says cool things have to cost a lot of money, go out and make life happen.
Soundtrack to stage building 101 provided by Antiseen and Crank County Daredevils
Usually the best ideas are the most simple and the ones in which you kick yourself thinking, why didn't I come up with that. Leave it Josh over at Brown Dog Welding to do just that with some of the new keychains for sale. Many of the pieces that Josh makes are just too damn cool and he has a lot ingenuity behind that welding helmet. We are hoping one day soon to work with him on a few ideas we have for custom belt buckles.
