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PVC conduit star tutorial

Discussion in 'Tips and Tricks' started by diyer, Jun 5, 2017.

  1. diyer

    diyer Full Time Elf Generous Elf

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    Hi guys and gals,

    It's almost complete now, but I was thinking that I should have done a 'how to' make a 20mm conduit star, especially how I cut the joins. I still have part of the jig that I used so I thought that maybe some of you might need some guidance so I would do a short tutorial.

    You will need some basic hand tools and a few off cuts of timber etc.

    Hacksaw
    Handsaw for cutting wood
    Cordless or electric drill
    20mm or 3/4" hole saw (mine was a cheapy from eBay)
    Heat gun (or hairdryer)
    Clamps
    File
    Assorted screws.

    Ok let's make a start. I used a 20mm conduit 'T' for the centre of the star and hole sawed additional holes for the additional vertical and diagonals. I can supply the dimensions if you want them.

    Now for the more difficult pieces. Mark the long shallow angle onto the conduit and cut with a hacksaw. I use my trusty B&D Workmate but just as easy in a vice or clamped to a bench.

    2017-06-04 14.07.11.jpg
    2017-06-04 14.08.47.jpg

    If you require a lot of these angles all the same, which you will if you are making the star, I would mark and cut them all now.

    Apply some heat to the cut area, you won't need a lot, PVC has a low softening temperature, once warm and malleable push the cut onto something that is the same diameter as the conduit to form a nice radius.

    2017-06-04 14.11.19.jpg

    2017-06-04 14.12.20.jpg

    I used a metal handle of a broom, the metal will cool the PVC quickly.

    2017-06-04 14.12.31.jpg

    Note in the picture that the cut gets deformed like an indentation, this is a great way to get a good bonding area when you glue it together.

    Now to the jig, mine was just a few scraps of timber and MDF that I had laying around, two pieces screwed to the top to hold the part that that you are making, another piece of conduit to set as a length stop so all the holes are in the same place, this could be screwed, but I just clamped mine.

    2017-06-04 14.50.02.jpg

    To be continued
     
  2. OP
    OP
    diyer

    diyer Full Time Elf Generous Elf

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    The length stop

    2017-06-04 14.50.59.jpg

    Now the drilling jig, another off cut, mine was a piece of 65x35mm pine. Mark and drill a pilot hole 10mm from the edge, then hole saw a 20mm hole, this will be your guide.

    2017-06-04 14.32.48.jpg

    2017-06-04 14.34.54.jpg

    Mark the position of the proposed hole sawed join on your star part


    2017-06-04 14.16.00.jpg

    Slide it into the jig so that the angled end is hard up to the length stop. You will now need the set your drilling jig in the correct drilling position, a little cutting of the jig might be required to place this correctly, once correct clamp in place.

    TIP, when I made mine I made two extra angled end pieces to practice the hole saw cut end, I only wasted one of these to get it right.

    2017-06-04 14.41.54.jpg

    Now for hole sawing, Clamp the conduit component piece in place and hole saw through the jig.

    2017-06-04 14.42.23.jpg

    How do I get more than six photos on a page!
     
  3. OP
    OP
    diyer

    diyer Full Time Elf Generous Elf

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    Last page..
    Clean up with a file and trial fit.

    2017-06-04 14.43.08.jpg

    2017-06-04 14.44.33.jpg

    2017-06-04 14.47.02.jpg

    If ok proceed to cut the rest.

    This method gives you nice looking and more important strong joins. Good luck!

    Any queries? Ask me..
     
  4. videoman3857

    videoman3857 Full Time Elf

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    Sweet as..Thanks for sharing
     

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