Just a little copper pot

[DSM Loki]

Hello all, after posting a couple pics in my intro thread I was recommended to start a new thread to document this thing going together. This is what I've got going so far. I shaped the frustums by working them over a section of 4" pipe. If you pay attention and keep whatever you're using as a mandrel running on the axis that is perpendicular to the top/bottom planes of the frustum it'll roll itself into proper shape real quick without inducing any twist.

These pictures are after about 10 minutes of forming in my living room and haven't been riveted yet. I'll be back in the workshop throughout the weekend and I will post more pics and update as I make progress.

[Sungy]

That looks sooooo sweet.

[bellybuster]

my oh my, will be watching this one.

[SassyFrass]

my oh my, will be watching this one.

Ditto. Definitely want to see more.

[WalkingWolf]

Thanks DSM -- I knew there would be a significant level of interest/appreciation and didn't want your build to be lost. Looking forward to updates.

[DSM Loki]

Wow guys, thanks for the kind words so far. I honestly didn't expect this thing to generate any interest, especially with how much more needs to be done. I should have some updates later tonight.

Edit: I should mention that this is my first attempt at building one of these myself, so don't get your hopes up too much about this being pretty when it's done.

[jedneck]

Copper is always petty. Looks good keep at it.

[W Pappy]

Looks good friend take your time don't get in no hurry and she will come out fine.
Now get er done so we can see some more of that perty stuff lol.

[firewater69]

Very Very nice work!!!

[shadylane]

More copper porn

[DSM Loki]

Well, I forgot to snap some pictures so I'll have to get those tomorrow but the lyne arm is taking shape, the main body of the pot is shaped, seamed, and riveted, and the body of the cap is riveted. All that's left is shaping the pan for the bottom, the pan for the top of the cap, and finishing the lyne arm. The fittings I need to get the thumper and liebig up and going should be in monday and I'd like to have the rest of this stuff finished up before then.

[Danespirit]

That thing looks great! You made a very professional start there..are you working with metal for a living?

[humbledore]

The first pics... You did that in your living room? You have skills, sir.

[Bushman]

I agree with the others, it looks beautiful. As you continue can you give us a bit more documentation? I am thinking along with photo's things like weight/gauge of copper, what size still your building, where you purchased your material, how you drew up the plans and layout, assembly techniques, etc. I know this is extra work on your part but for any members that want to follow it would be a great guide to document the steps with suggestions etc.
Thanks, Bushman

[DSM Loki]

That thing looks great! You made a very professional start there..are you working with metal for a living?

Thanks. I build engines for a living. I've done a good amount of sheet metal work building parts for race cars through the years, but all of that has been flat plane. This was my first attempt at forming anything round or cone shaped.

The first pics... You did that in your living room? You have skills, sir.

Thanks, yeah. I used a 4ft section of 4" pvc leaned against the couch and worked back and forth pushing the sheet against it until the ends overlapped and my marks lined up.

I agree with the others, it looks beautiful. As you continue can you give us a bit more documentation? I am thinking along with photo's things like weight/gauge of copper, what size still your building, where you purchased your material, how you drew up the plans and layout, assembly techniques, etc. I know this is extra work on your part but for any members that want to follow it would be a great guide to document the steps with suggestions etc.
Thanks, Bushman

Thanks Bushman. Yeah, no problem. I'll be working on it some more today and I'll remember to snap some pics.

As for material, I'm using .0216/24ga/16 oz copper sheet from https://www.guttersupply.com If I ever end up building another of these I'll probably use thicker material for the bottom, as I prefer propane heat, but I don't expect to have an issue.

All of my fittings, rivets, solder, flux, etc. have been sourced from http://www.mcmaster.com Once they all get here tomorrow and I can verify fitment and that I ordered all the right things, I'll post here with an itemized part list.

[DSM Loki]

Ok, quick update. I trimmed up the opening on the top of the cape, resized the collar to match, marked the spots I'm riveting the collar, verified cap to collar fitment, and finished shaping the lyne arm. Once I strip the exif data and resize the pics I'll upload them in another post.

One thing I'm a bit unsure of is how I'm going to attach the cape to the body. I welcome any and all suggestions. The body diameter is 20". I have a little excess material on the cape to work with, It comes out to a 21" diameter. Should I cut some vertical slits around the perimeter and fold tabs down to make it an interference fit on the inside and just flow some solder to attach it? Do I just trim it a bit to clean up the edge, leave a bit of overhang where it meets the body and solder it where they meet? Cut slits, fold tabs down so it has an interference fit inside the body, drill a hole through the body into each tab and ride the strugglebus to hammer rivets in each one?

Edit: Looks like I might have to make a 20" diameter form and hammer the edge down to make an interference fit into the body and solder it in place, or maybe have a buddy TIG it in with copper filler.

Edit 2: I forgot to mention, the lyne arm has a tight fit in a 4" pvc pipe on one end, and a tight fit into a 2-1 reducer on the other. I'm not looking forward to trying to rivet it together but I'm sure I'll figure something out.

[DSM Loki]

Sorry for the lack of quality on the pics, I don't have a digital camera or a smartphone.

[W Pappy]

Looks damned good there friend keep up the good work!!

[rager]

Looks damned good there friend keep up the good work!!

looks awesome. those pics don't do it justice. when your finished borrow a friends camera and get a finish pics posted

[DSM Loki]

I do have a few professional photographers for friends, I'll see if I can arrange a shoot when it's all done.

[rager]

I do have a few professional photographers for friends, I'll see if I can arrange a shoot when it's all done.

hell yea!

[jedneck]

Im in luv.

[Halfbaked]

WOW! That is really nice

[just sayin]

She is a stunner! Great workmanship, please keep the pictures coming!

[DSM Loki]

I worked on it a little more tonight. The collar is riveted, the pans to make the bottom of the body and the top of the cap are starting to take form. I also figured out how I'm going to get the rivets in the lyne arm. All I have left to do is fold down a little lip on the cape to stuff into the body, finish forming the pans, and finish riveting everything and I'll be ready to flow some solder.

[Warrior Chief]

Sexy suddenly took on a whole new meaning for me! You formed that in you living room? WOW.

[heartcut]

Those are some gawdaful pictures of outstandingly beautiful work. Please keep it coming.

[SassyFrass]

Wuv, true wuv....

[DSM Loki]

No more pics yet, sorry guys. I got the rivets in on the lyne arm today and got my new burner. It's a bayou classic sp40. High pressure dual jet propane setup. It'll be far more than I need but the price was right and more importantly, the stand is super sturdy.

[DSM Loki]

Another update without more pics yet, got the bottom pan shaped and riveted into the body of the boiler. Started cutting the hole in the side of the cap for the lyne arm to attach. I'm going to fold some tabs out from the large end of the arm, stick the arm through the hole from the inside of the cap, rivet the tabs to the cap, and then solder it together to seal.