First attempt to make endplates

[Pat Comeau]

here's some endplates i'm making for my next projects, it took me 2 days to grind, file ect... to the stage you're seeing and it's still needs alot of sanding before buffing , it's a heck of a job doing it this way, it was welded with an arc welder with aluminum rods, i've buffed it a little to see how it would look and you can see the different color type of aluminum from where the welding was done from the rest, you really have to look close to see the difference , i don't know yet if i'm gonna use them or not i guess i'll have to wait until the're all buffed out, if i don't put them on my next guitars i'll use them as temporary endplates.

Before

[Pat Comeau]

After 2 days of sanding grinding filing ect...oofff..............

[burt]

Pat,
I've got my toolmakers hat on.

Before you spend a lot of time buffing the endplates, drill and tap the leg sockets.

If you make a hash of drilling and tapping (which can easily happen ) then you won't have wasted any time finishing the item, and can start over without too much time invested

[Bent]

Pat, that is a courageous first attempt. My hat goes off to you!
I strongly recommend that if you decide to weld them together(instead of machining out of 2X4" stock) invest the money and get them TIG welded. When welded, the seam is invisible. Also, you have no spatter plus the weld itself is way neater, slimmer, stronger and prettier with lots less cleanup.
I have to ask what are the 2 vertical welds on the face? Normally you cut 3 pieces; one front and the 2 sides for welding. V out the corners so you fill with weld and then grind/sand/polish to an invisible finish. There should be some pics on my photobucket site.
One disadvantage with welding is that it is near impossible to avoid warping from the heat. They shrink when cooling. Make them about 1/16" over length.

I have a welder here. He's as good as they come. He can weld two coke cans together.

[Pat Comeau]

Pat,
I've got my toolmakers hat on.

Before you spend a lot of time buffing the endplates, drill and tap the leg sockets.

If you make a hash of drilling and tapping (which can easily happen ) then you won't have wasted any time finishing the item, and can start over without too much time invested

Thanks Richard, i was thinking the same before the buffing and final sanding.

Bent wrote=

I have to ask what are the 2 vertical welds on the face? Normally you cut 3 pieces; one front and the 2 sides for welding. V out the corners so you fill with weld and then grind/sand/polish to an invisible finish.

Bent,
it is because i've used a 3" angle and cut it that way but...i think the other way like you said is much better to do ,with less effort to grind ect..., if i do some more welded endplates i will do it the other way like you did with yours, i'm looking to buy a mig welder 220V with a spool gun for welding aluminum...this is something i really need around the house and not only for building PSG, i will post pics of the endplates when i'm done with them.

[Bent]

PAt, MIG is so so for aluminum. TIG is by far the best.

[Pat Comeau]

PAt, MIG is so so for aluminum. TIG is by far the best.

and by far the most expensive like $2000 to $5000 for something good, compared to about 800$ to 1500$ for a good mig.

[Bent]

That's true. But that is where a welder with TIG comes in. He can weld up a set of endplates in an hour..at $50 an hour. That would be the best and cheapest way to go.