Metal & Wood
Priscilla & Luke Smith
This video was made in partnership with BESSEY Tools North America.
In the first video we showed you what you can do with different tools and materials, and covered all the prep and safety measures. In the second video we’ll take you through each step in welding together a base for a side table as just one way to start incorporating metal into your woodworking projects. You’ll want to watch both videos to get the most information, and to make sure you walk away feeling confident to get working on your next metal project!
Grab your PPE and let’s get down to business! Having the proper protection when working in a shop is always one of the most important things, and working with metal makes no difference. You always want to make sure you have the proper eye protection, ear protection, a good pair of gloves, a respirator, a fire extinguisher, and when welding, a quality welding helmet/goggles and a welding jacket.
An early step in the process of working with metal if you plan to weld it is to first clean it. Cleaning off mill scale can be done with an angle grinder with either a wire wheel (if the layer of mill scale is fairly thin) or sanding flap disc. When going the route of a flap disc, keep in mind the grit. A coarser grit disc will take off the mill scale faster but leave grinding marks in the steel. If you’re after a smooth surface finish in the end result, progressing through the grits until you reach the desired finish will be required.
When using an angle grinder, it’s crucial to safely hold it in place. A vise can work great for this, but sometimes it’s easiest to use a BESSEY F-style Clamp and hold it tight to a workbench. BESSEY has F-style clamps that can range from 600 to 5000 lbs of clamping force, but for this application, you only need enough clamping force to hold the part still, so a light duty clamp is absolutely capable of doing so. The last thing you’ll want to do after grinding off all of the mill scale is to wipe down the steel with some acetone.
Once your metal has been prepped to ensure a good weld, it’s time to cut your parts to size. This is no different than working with wood other than the method by which you might employ to do the actual act of cutting. You won’t be using a regular miter saw or table saw to cut your metal down to size. We love using our horizontal bandsaw! These have a vise built in that holds material still and often have a removable work stop for making repeatable length cuts.
If you’re thinking about how you’ll fasten a wooden top to your metal base, your project may need some holes drilled in it and there are a few differences when drilling into metal compared to wood. The most important thing is to use a center punch to leave a little dimple where the hole will be drilled. This allows the tip of the drill bit to have a registration mark, ensuring it stays centered for the hole to be drilled. Without center punching, the drill bit will have a tendency to skate around on the metal, possibly drilling the hole in the wrong location.
Another important factor when drilling holes in metal is the speed or rotations per minute (RPMs) of the drill bit. In metal, you want the RPM to be much lower than it would be when drilling a hole in wood. This has an effect of the heat build-up in the drill bit. In addition to using a lower RPM, you’ll want to use some sort of lubricant to act as a coolant to extend the life of the bit. A spray of WD-40 works just fine, but there are various cutting fluids that you can drop a dab of on the hole before and even while drilling to keep the bit cooler. Our preferred type of drill bit to use when drilling holes, particularly in steel, are cobalt drill bits. Being made of cobalt, they have a higher resistance to heat, therefore stay sharper longer in comparison to bits made of other materials. We have a 29 piece set from Montana Brand Tools that we absolutely love.
Let’s get to the welding! Just as wood can warp with exposure to moisture, metal warps with exposure to heat. The intense heat applied when fusing pieces together causes the molecules in that area to expand and after rapidly cooling and contracting, the metal will develop a warp in it. The best way to combat excessive movement in the material is by applying enough clamping pressure to overcome the internal forces moving the metal, keeping everything lined up and in place.
If you want a fixture table to get started with, Lincoln Electric makes a great portable folding fixture table that you can combine with some of BESSEY’s fixture table clamps to easily hold parts in place. They have clamps with a fixed throat depth and even ones with a variable throat depth that allow for greater flexibility when fixturing components. For even faster securing of material, BESSEY has horizontal auto-adjusting toggle clamps that attach to a toggle clamp adapter plate that keep a low profile, making it easier to maneuver around when welding. While a fixture table isn’t 100% necessary when starting out, we’d highly recommend one for a more efficient work-flow, especially if you don’t currently have a metal surface to weld on.
We aren’t able to get into the ins and outs of finishing metal in this series, so here’s an excerpt from ChatGPT:
When it comes to painting or sealing metal surfaces, there are several options available depending on your specific needs and the type of metal involved. Here are some common choices:
Oil-Based Paints:
Benefits: Oil-based paints provide a durable finish that is resistant to abrasion and moisture.
Suitable For: They are suitable for both indoor and outdoor use on metal surfaces such as fences, gates, machinery, and furniture.
Considerations: They typically require longer drying times and proper ventilation during application.
Acrylic Enamel Paints:
Benefits: Acrylic enamel paints offer a tough, glossy finish that is resistant to fading, cracking, and peeling.
Suitable For: Ideal for automotive applications, metal furniture, appliances, and other high-use items.
Considerations: They can be applied with a brush, roller, or spray gun and generally have a quicker drying time compared to oil-based paints.
Spray Paints:
Benefits: Spray paints provide a convenient way to apply an even coat of paint to metal surfaces, including intricate details and hard-to-reach areas.
Suitable For: Perfect for small projects, DIY crafts, and touch-ups on metal objects like tools, outdoor furniture, and household items.
Considerations: Ensure proper ventilation when using spray paints, and follow the manufacturer’s instructions for best results.
Rust Inhibiting Primers and Paints:
Benefits: These formulations are specifically designed to prevent rust formation on metal surfaces by creating a protective barrier.
Suitable For: Essential for bare metal or surfaces prone to rust, such as iron gates, outdoor furniture, and automotive parts.
Considerations: Apply multiple coats for maximum protection, and choose products that are compatible with the type of metal you are treating.
Clear Coats and Sealers:
Benefits: Clear coats add a protective layer over painted or bare metal surfaces, enhancing durability and gloss.
Suitable For: Used to seal in and protect underlying paint layers from weathering, scratches, and UV damage.
Considerations: Choose a clear coat that is compatible with the type of paint or finish you have applied for best adhesion and longevity.
Powder Coating:
Benefits: Powder coating provides a highly durable, chip-resistant finish that is applied electrostatically and then cured under heat.
Suitable For: Ideal for metal furniture, automotive parts, appliances, and outdoor equipment requiring a tough, long-lasting finish.
Considerations: Requires specialized equipment and typically done by professionals due to the curing process involving high temperatures.
When selecting a paint or sealer for metal surfaces, consider factors such as the intended use (indoor vs. outdoor), environmental conditions (humidity, UV exposure), and the desired aesthetic finish (matte, gloss). Always prepare the metal surface properly before application to ensure good adhesion and durability of the finish.
Back to the build! Now that you have your base securely welded, finished with your choice of paint, powder-coat or sealer, and ready to affix your wooden top, take a few minutes to align it without fasteners and ensure you like the look of it before you go further. It may be a good idea to consider marking through your metal base holes onto the bottom of your wooden top and pre-drilling into your wood. The last thing you would want to see happen at this point would be an overly aggressive fastener causing the wood to crack! If you didn’t take time to glue up your own custom top, heading to a big box store and grabbing something like this 15” radiused pine round is a nice cheat code to getting a jump start on a simple DIY project!
We hope this info was a good introduction into the knowledge needed to make a cool project out of both metal and wood!
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