In response to the article on the Speedy Lack Assemblage Companion Kit (S.L.A.C.K.), we’ve now re-created a better one. This one is welded more professionally, looks neater and offers superior grip over version 0.9 of this tool. This tutorial shows you everything on making a SLACK.
Step 1: Ingredients
Get ahold of something similar like this. Any hardware store sells this stuff for about a few quarters. The sizes are important in this case, since it needs to fit smoothly around a 5*5 centimeter square. Depending on your tools its possible to use larger shelf-holders and grind/cut off the part you don’t need.
Step 2: Required tools
This tutorial uses a lot of power tools. Be sure to be familiar with these tools and that you’ve had proper training or education before using them. They can do a lot of harm if not handled correctly. For example: make sure they are OFF when you plug them in. If you don’t have to skills, consider other alternatives to make a SLACK.
Welding
- Welding equipment: Gude Inverter GC 100 PM (art nr 20056)
- On the lower settings (below 40 amps) since the iron used is very thin.
- Slag removal tool and brush (see above)
- 2mm electrodes
- Welding clothing: welding cap, apron, gloves, shoes, etc
- Welding table (pref in a workplace or outdoors)
- Rare Earth magnet (about 5 centimeter) to hold things together
- Grip plier
- Assorted clamps you have anyway in case you need them
- Extra metal for heat distribution
Grinding and polishing
- Power grinder: Black & Decker KG915, Type 2. 10.000 rotations per minute, 115 millimeter blades.
- Small grinder / brusher: Dremel multipro. 10.000 to 33.000 rotations per minute. Model 395.
- File: bahco 100-08-1
- Vice: paramo hi-duty vice #2 (or similar)
- Hacksaw: Bahco 320
- Safety glasses
Enough lighting and workspace. Also a clear mind and energy.
Step 3: Welding the square
We start with the hardest part: welling the square. This requires some extra metal to distribute some of the heat.
Be very carful and sensitive when welding these parts together. The iron is very thin and cheap: it’s gone before you know it. If you can get hold of 1.6 mm electrodes use those, as they require even lower amperage to operate and thus get less hot.
Use the grip plier, together with the rare-earth magnet and extra metal to make sure the edges of the shelf-holders are held together. See picture:
The opposite side is much easier. Only the grip plier is needed. After welding the sides, this is the result:
Step 4: Adding the surface
The hardest part is over. Now to add the surface. We need the rare earth magnet and some patience in placing it right. We use a pre-shaped one with a hole exactly centered. Make sure it’s perfect center.
After welding the usual slag needs to be removed. Use the tool that is included in the welding kit.
Step 5: Grinding
From intense heat, we move over to sparks. Using the power grinder we remove the excess slag and any oversized
Step 6: Handle
Now for the handle. This part will make sure the SLACK will fit in an electric drill. In our case the thread is a little too long so we made it shorter using a hacksaw.
Also the grip (nut and bolt) need to be welded. This is similar to adding the surface: weld the nut and bold to the flat surface. Welding these can be very tricky, try to evenly heat both the nut and the surface below it. Otherwise you sand up with a blob of metal on the nut alone.
Now for the sparks. Use the grinder to add some grip on the screw threat. This always looks spectacular.
And now we have a handle:
Step 7: Details
With the Dremel and file we make sure everything looks good.
The nut and bolt need to look smoother. This makes some awesome sparks.
Now to polish the surface.
Step 8: Finished!
Here we go, a complete Speedy Lack Assemblage Companion Kit (SLACK).
By Igor (powertools) and Stitch (documentation). Made at the RevSpace.