Emergency Upgrades

Tonight was our first batch of test sandwiches.  They were delicious, but use of the griddle on top of the wagon revealed a last minute problem.  The piping hot griddle needs to be stored, but everything inside the wagon is plastic.  Only one solution... an 11pm emergency ride to TechShop.  Luckily 2 friends from Atlanta, Jeff and Ross were visiting, and Jeff volunteered as stoker (the guy in the back).

A few quick steel cuts and MIG welds later, and there's a new small compartment on the inside of the upper half of the wagon for hot griddles.

The final major piece on the wagon was the chandelier mount.  Yes, chandelier.  Here it is being formed by the most dangerous object in TechShop, the acetylene torch.

There were a few small minor explosions in the tip of the #8 rosebud torch (the biggest one) when I tried dialing in the flame.  Luckily a TechShop master welder walked by and told me it was an inherently crappy and dangerous tip, and got me setup with the cutting torch for much easier bends.

And here it is attached in all it's epic bent steel glory.  There's a twist at the base to get it centered over the cart.  It sockets into a sleeve mounted to the top of the frame for daytime removal.

Countdown to cheese

Holy crap sports fans, it's game time. We are leaving for the burn in TWO days.

Sorry updates have been sparse in the past couple of days, but we have been busting our buns getting stuff done. For instance, I made 100 burritos this week....

But rest assured we are getting cart stuff done. So here is a quick update for your fans of grilled cheese (Hi Mom!). I'm amazed that we've had almost a thousand page views! I know that's not a lot by internet viral standards, but considering I made this so my mom and a few friends could follow along, it's impressive. 

Fabrication on the cart is done. Well its 95% done. It's damn close enough. Tweaking will continue as time allows.  

Decor of the table has begun. The big debate of today is to placemat:

or not to placemat...(sorry that's upside down- no time to fix it!). All of these things will be epoxied in place so the table is always "set".  Note yet another change in table cloth occurred- the paint on the wagon came out a bit orange, so back to the fabric store I went. I would love to have a fake napkin on their to complete the picture, but I need something that looks like napkin, but can be vigorously cleaned so it doesn't become a harbor for germs and dust. Perhaps more vinyl....

I am debating if I really want to glue my delightfully cheesy kissing surfers salt and pepper shakers..... 

They make me smile, and I would be uber sad if I lost them. It would be nice if people could actually use them.. perhaps they can just get set out for each guest. 

God this apartment looks like a theme camp blew up in it. No time for cleaning! BACK TO WORK. 

Sweet Jesus! It's actually coming together!

I've recently gotten some time to work on the lighting portion of the wagon. I have spent some time playing with microcontrollers so I decided to go one step down the food chain and play with ICs. I'm taking some 555s to trigger cycling in an RC circuit. The oscilloscope is displaying the voltage in the capacitor over time. I'm going to build circuits with different adjustable resistors so the timing is slightly off between them. Each one will power a different color in some RGB leds. It should give me a nice color cycle.

The wavy lines means it's working.

Alcohol is the solution to all problems.

Moving from the breadboard to a prototyping board.

Close up of the prototyping board with RC circuit components mounted. 

I also joined Chris last Sunday for some metal work. Chris has been busting his ass all week and it shows. We finished the last piece of sheet metal, came up with the initial cooler layout and did a fair amount of powder coat work.

Cutting the initial hole to access the cooler. Note how rough the hole is at the lower right hand side.

Really wishing we had used the water cutter to make the hole at this point.

The sand blasting "protective" glove had gaping holes in the thumb and forefinger. Considering this was Chris' hand I figured duct tape was an acceptable repair mechanism.

Dear God, please let me stop sanding this aluminum...

The first step to powder coat aluminum is to sand blast it. In theory this greatly increases the surface area and removes most blemishes. Since we never actually tried powder coating without this step this might be the metal shop version of a snipe hunt.

2,000 volts + paint = awesome sauce[0].

[0] For definitions of awesome sauce which involve a nice even coat of pigment.

Putting the metal in the oven. I wish I had a picture of all the melted rubber in this oven where people used their shoes to keep the door from searing their elbows.

First batch done! It actually looks professional as well.

Stay tuned for pictures of the assembled wagon.

Sammies are Metal

There's been tons of progress on the metal of the Sammie Wagon.  Here's some shots...

As Hunter says, when parts don't quite fit, we can just "fix it in post".  Well, here's post.  I'm about to hit this door with a hammer many times to make it the right size.  The wood is to make sure it bends where I want instead of deforming into a lump.

The initial placement of the hinges allowed for a full 270 degree door open, but was a little ugly in how far out it pushed the door when closed.  To fix this, I ground all the hinges off (they were welded onto the frame).

After grinding them off, I mounted them on the doors, and clamped them in their final homes for a bit of welding.

In the end, mission accomplished:

Sheet metal can be pointy, so if spend you enough time abusing it, it will eventually abuse you.

Luckily, I have the tools to repair this construction issue available in the shop.

I need some corner molding to cover the 3-way joint on the top of the wagon, so I gave welding them myself a shot using the 20 guage aluminum the skin is made out of.  Turns out this is one of the hardest things to do in all of welding, and something people show off with to prove their ultimate welding mastery on youtube.  Here's the rig I made to mount the aluminum on for welding, and my failed attempt.  I got points from TechShop attendees for at least having plenty of "ambition".

The skin of the cart is almost fully fabricated, so it's time for powder coating.  The final colors are kitschtastic Ford Light Blue for the sides, and a lovely red for the counter top.  To powder coat parts, you stick the powder on with an electrically charged powder sprayer, then stick them in this huge oven to melt the powder  into a sexy, shiny, protective coat.

Here's the 2 test panels.  The blue includes a layer of clear, with some glow in the dark additive.  No idea if this will actually work on the playa, but I can confirm seeing the panel in the dark of the TechShop bathroom after a few seconds of fluorescent charging.

Finally, victims of the Sammie Wagon need somewhere to sit, and I thought I'd have to fabricate a mount to hold their seat.  Turns out, we are geniuses, and the removable table already accomodates the chair.  This shot also shows the new mounting bars for the grill, and the future home of the grill cheese access top panel.

Soon, final powder coated skin on the cart...

It's not all about the metal.

We certainly have had a very focused discussion about metal so far.

But really the metal cart is only a small part of the big picture.

There are costumes being sewn for instance. Today I finished this apron to go with my rockabilly look:

So. Many. Fucking. Ruffles.

My eyes are crossing and my shoulder hurts. Time for a little vino therapy.

SAFETY THIRD

So, despite the fact that we do have other authors I take primary responsibility for updating this blog. I see this as a fair trade. I'm a gimp right now, so I have very little physical labor that I can perform in the quest for grilled cheese perfection. I can procure things and I can type. So in this role, I often receive pictures from my partners in crime so that I may share them with you.

This was the first set of pictures that made me vomit in my mouth a bit. I had to check the urge to lecture my husband and his playdate like school marm going after errant toddlers for eating crayons.

Let me explain via this fine photo journal. It's time to put the "skin" on the cart. Last stage before paint and final assembly. VERY exciting indeed.

So, because of the mix of a steel frame and aluminum skin, we are bolting this on. This means many holes must be drilled. A hand drill would do the job. It's tedious, but safe. The cart is too unwieldy and large to put on the drill press that is available.... right?

Chris? Chris, what are you doing with those blocks of wood near the drill press?

Hunter?! Seriously right now, what the fuck are you thinking? That is not a stable platform. That is an industrial drill press. Come on guys- you are smart men. I know testosterone is not a smart drug, but certainly some level of basic common sense will intervene here.

Apparently not.
Gee Chris, you look frustrated. Could that be because you are using a tool in a non-approved manner and you are ABOUT TO FUCKING KILL YOURSELF.  Please note the spiderman bandaid on my husbands forearm. He burned himself last week because he forgot that metal that he had just welded might be a bit warm. That incident may have been a signal that something might be wrong with him.

And just in case you thought the stupidity could not get any deeper...

Really!? Is that a godforsaken jack? Is that thing even level!? Seriously you guys. *headdesk*

Shockingly the bit on the drill press exploded. I can't image why.  I bought him a new drill bit. I'm going to trust its going in a hand tool this time.

Bang Bang.

Good news! The state of Nevada has declared that I am fit to serve food to you on an extremely temporary basis. This was one of those scary government hoops that if it didn't go through all of this time, money and effort would be for nothing. But no worries. Our permit came in the mail today.

We are 90% done with metal fabrication.  So lets get to the pictures, that is why you are here afterall.

So, let's check the now raggedy set of plans that have been shoved in Chris' backpack. Yup, they still look raggedy.

Safety third.

Ear protection is important- you must save your virgin tympanic membranes so that you can fully enjoy this music of the playa... on second thought maybe I won't wear these. 

Okay, let's do some welding! We are using MIG welding here. It is like someone decided to mix a hot glue gun with a welding machine. What we are attaching in the picture below are the frame brackets for the table. The table is designed to fold in and out. Someone (ahem) came up with a brilliant stable design to allow this to happen without hinges and locks, etc.  Bascially there is a L shaped bracket on the table that fits into these post on the frame. In one arm it's extended, in the other it's locked in place for transport.

Now we weld the frame for the table itself.

So here we have the table in the extended position. 

And here it is in the collapsed position for transport. 

So really that's all the big stuff. We're down to the nitty gritty now. We have to drill all the panels to mount them with bolts, paint it (powder coat came this week) and decorate it. 

Oh.. and Chris has to figure out how to make corner covers. His first idea didn't work out so well...

Light up the night.

You know Burning Man is around the corner when  you are trying to fit stuff like this in to your 900sq ft apartment in San Francisco.

So it has been a busy week here in the Jurney household. Time is ticking away and we are diligently working on our projects to get them done. We're nearly done with the bike lighting.
It has been professionally wrapped with LED rope

There is no good way to photograph this. Once its 100% wired I'll do a lit pic in a dark room.

Much wiring has been done. I will say, unlike the really great LED rope in the video link I gave last time, the stuff we bought from amazon has a really annoying plastic coating that we (Chris) had to dremel off to solder our wires. 

Prooofessional.

So protection from the elements of your delicate electrical parts is super important in the highly corrosive environment. All of our solder joints are taped, heat shrink wraps and taped again. And the our batteries will live in this hilarious kids snack box from Target:

We wired the switch for the lights as his nose. You know you love it. Well I love it. It makes me giggle still.

Chris and I also went to techshop last night and did much metal working. Probably another 2 to 3 days of metal working and the cart will be done. Then it will be time for paint and decor :) Can't wait!

I'll post pics of the metal shop experience later. Happy Thursday!