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Editorial
ISSN: 1177-0457
EDITOR
Greg Vincent, editor@theshedmag.co.nz
SUB EDITOR
Sarah Beresford
TECHNICAL EDITOR
Jude Woodside
PROOFREADER
Some things just Odelia Schaare

DESIGN
Mark Tate
make sense STAFF PHOTOGRAPHER

Adam Croy
T
CLIENT SERVICES MANAGER
here can be no doubt that the weather are doomed, but there is no doubt that we
Rebecca Frogley
is right at the forefront of our thinking need to make sure we are secure in many ADVERTISING COORDINATOR
in our daily life, especially at this time more ways that we have been used to for Renae Fisher
of year. It often leads the TV and radio most of our lives. It seems that droughts are CONTRIBUTORS
Sue Allison, Mark Beckett, Jim Hopkins,
news bulletins and is no stranger to the now a factor of life every summer. Even if Juliet Nicholas, Coen Smit, Jude Woodside,
front page of the paper. the end is not nigh, it would still be great to Bob Hulme, Raf Nathan, Juliet Nicholas,
You can say and think what you like about keep the garden going strong through the Richie Wilson, Nathalie Brown,
Derek Golding, Chris Slane,
climate change but there is no denying that, hotter months — there’s nothing sadder than Sarah Beresford, Enrico Miglano,
nowadays, we just can’t escape the constant ZLOWLQJYHJJLHVDQGGHDGÁRZHUV Lachlan Jones, Adam Croy
weather barrage. It goes without saying that The result of this thinking is the reason
SUBSCRIBE
this is not just a media beat-up — many of for our main feature this issue — some ONLINE: magstore.nz
us Kiwis are experiencing these extreme basic guidance to help you secure your own PHONE: 0800 PARKSIDE (727 574)
POST: Freepost Parkside Media Subs
weather events on a much more regular rainwater supply. Even if you live in a city, PO Box 46020, Herne Bay, Auckland 1147
basis. It’s either hotter, wetter, windier, or setting up a supply is not rocket science and EMAIL: subs@parkside.co.nz
drier than we have ever known it and it’s not it just makes sense to do so. Tanks come in
CONTACT US
going to go away or get better. It’s going to all different shapes and sizes these days and
get worse. So, what are we sheddies going to there are options galore for that awkward PHONE: 09 360 1480
do about it? space that is the only place you can really FAX: 09 360 1470
Our theory is, because we can, we do — or, install a tank. The options, too, for gathering, POST: PO Box 46020, Herne Bay, Auckland 1147
EMAIL: info@parkside.co.nz
more important, because we can, we should. cleaning, pumping, etc., are also plentiful
Many sheddies have the skills to sort some and varied. Think about it — you will regret PUBLISHER
of our own needs and not be so dependent not arranging your own supply every time Greg Vincent, gvincent@parkside.co.nz
GENERAL MANAGER, BUSINESS DEVELOPMENT
on infrastructure to completely look after us. you get that water bill and for sure that
Michael White, mwhite@parkside.co.nz
If we can ensure that we can have our own water cost is only going to go one way. If you GENERAL MANAGER, OPERATIONS
water supply we should. If we can ensure that are not paying for your water now, there is Simon Holloway, sholloway@parkside.co.nz
we have our own power supply, etc., then we nothing more certain than you soon will be. PRINTING
PMP Maxum
should. Many of our neighbours can’t solve So dive into our rainwater feature this
DISTRIBUTION
these kinds of issues for themselves, so by issue (page 22), and plan to arrange your Gordon & Gotch
sorting ourselves out we are lessening the own supply before next summer — the PHONE: 09 928 4200
load on the local infrastructure. To us, it resultant saving will have you singing in the
seems logical to look after ourselves when shower like never before. NOTICE TO ADVERTISERS
Parkside Media uses due care and diligence in the
we can. In a crisis, we will be in a position How can that be a bad thing? preparation of this magazine but is not responsible
or liable for any mistakes, misprints, omissions,
to help others. Greg Vincent or typographical errors. Parkside Media prints
Now, I’m not prophesying the end of days Publishing Editor advertisements provided to the publisher but gives
no warranty and makes no representation to the
(not currently in my skill set) or saying we editor@shedmag.co.nz WUXWKDFFXUDF\RUVXIÀFLHQF\RIDQ\GHVFULSWLRQ
photograph, or statement. Parkside Media accepts
no liability for any loss which may be suffered
by any person who relies either wholly or in part
theshedmag.co.nz | Find us on Facebook | Subscribe upon any description, photograph, or statement
contained herein. Parkside Media reserves the
right to refuse any advertisement for any reason.
DISCLAIMER The views expressed in this magazine are not
No responsibility is accepted by Parkside Media for the accuracy of the instructions or information in The Shed necessarily those of Parkside Media, the publisher,
magazine. The information or instructions are provided as a general guideline only. No warranty expressed or the editor. All material published, gathered,
or implied is given regarding the results or effects of applying the information or instructions and any person or created for The Shed magazine is copyright
relying upon them does so entirely at their own risk. The articles are provided in good faith and based, where of Parkside Media Limited. All rights reserved
appropriate, on the best technical knowledge available at the time. Guards and safety protections are sometimes in all media. No part of this magazine may be
shown removed for clarity of illustration when a photograph is taken. Using tools or products improperly is reproduced in any form without the express
dangerous, so always follow the manufacturer’s safety instructions. written permission of the publisher.
The Shed 77 March/April 2018 1

Contents
ON THE COVER
Frozen in time
Rainwater harvesting
22 A guide to setting up and good practice to
collect water. Do it before you are made to.
114 Visit the shed of an Auckland refrigeration
manufacturing business which has shut its
doors for the last time
48 52 108
Make a bow BBQ trolley Steampunk toys
With these easy steps, we show you Trolley busted? Throw the BBQ away? Coen uses a vivid imagination to
LW·VQRWWKDWGLIÀFXOW Never, weld a new one create some extraordinary toys
Boardwalk racing motorcycle Oamaru Steam & Rail

38 A sheddie recreates a 1920 American racing
bike in his Christchurch shed
62 A team of enthusiasts keep the steam trains
running in the railway sheds near the town wharf
2 The Shed 77 March/April 2018

A cut above
4 Enjoy the work of two South Island wood millers who
have their own unique approach to prepping timber
74 84 90
Pottering about Soldering tips 3D Printing part three
A Canterbury sheddie creates unique Get a few tips and tricks in part one of We move up a level in our skills and
and desirable pottery a two-part series print out a camera
Every issue Fires Part 4

1 Editorial )LQLVKRI\RXUEORFNÀUHZLWKD
SHUIHFWSODVWHUÀQLVK
18 News: round and about the
world of The Shed
20 Readers’ letters
36 Subscribe to your favourite
Shed magazine
122 Back issues order form
124 0HQ·V6KHGVOLVWLQJÀQG\RXU
nearest group
126 Bookcase: get your sheddie
books here
128 Back O’ The Shed: Jim returns Going for gold
to Wigram Air Force base and
recalls what could have been 18 A Kiwi tradie takes on the
world and beats them all
106
Sawmillers

TWO SOUTH ISLAND SAWMILLERS ARE SOUGHT
AFTER FOR BESPOKE TIMBER PRODUCTS
AT EACH END OF THE SPECTRUM — ONE USING
CHAINSAWS AND THE OTHER TINY
HANDMADE BLADES
By Sue Allison
Photographs: Juliet Nicholas

Dave Neame:
chainsaw milling
S
entimentality and chainsaws
don’t usually go hand in hand but
Dave Neame uses the machines not
“That’s my shed. I can
to massacre but to preserve pieces of
wood for posterity. take it all round the
The long-time logger, who is based in country”
North Canterbury, uses his prowess with
a chainsaw to mill trees into slabs that
can be turned into furniture, kitchen
benches, or used as building features. stores his gear in a container in Okuku,
“I get approached by people who’ve but has a semi-permanent set-up for
got trees that have sentimental value and bespoke milling in a macrocarpa grove
WKH\ZDQWPRUHWKDQÀUHZRRGRUPXOFK on a friend’s property in nearby Ohoka.
out of them. I come and mill them up and A sign nailed high on a tree declares it to
they can get made into something that be “Dave Neame’s Thinking Forest” and,
becomes a family heirloom,” he explains. clad in leather chaps and earmuffs, he
is probably the only one who can think
Dave’s gear above the roar of his saw.
Dave’s mobile mill comprises a Kubota Dave has a range of chainsaws.
tractor and three chainsaws, which he His “baby saw”, which can cut up to
carts around on a trailer behind his 500mm, is a 92cc Stihl MS661, a fuel-
Nissan Navara — “That’s my shed. I HIÀFLHQWVDZZLWKDQLPSUHVVLYHSRZHU
can take it all round the country.” He to-weight ratio. His big double-end

Dave also makes signs out of timber slabs. He uses an electric hand router to cut out the letters
and images, which he draws freehand, then paints the grooves
Chainsaw chronicle
The prototype of today’s chainsaw was millwright James Shand.
a hand-operated device used for cutting In 1926, Andreas Stihl patented a
bone by doctors in the late 18th century. 116-pound (53kg) electric two-man saw.
A handle connected to a sprocket wheel One year later, Emil Lerp, founder of
turned the serrated chain. Dolmar, mass-produced the world’s first
In 1905, Samuel Bens, from California, gasoline-powered chainsaw, the Type A
patented the ‘endless chain saw’ (a saw, which weighed 125 pounds (56kg).
chain of links carrying saw teeth and McCulloch started to produce
running in a guide frame) as a means to chainsaws in 1948. The early models
fell giant redwoods. were two-man contraptions with
The first portable chainsaw was long bars, often so heavy that they
developed in 1918 by Canadian had wheels.
saw is an Alaskan Mill Mark III. With

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Process
Dave uses a standard 3.6m aluminium

ladder as his guide, bolting it to the
timber to be milled with two coach
screws. His smallest horizontal saw, a Stihl
MS 661, is connected to an adjustable
steel frame that allows it to be set to the
depth of the cut. The frame slides along
the top of the ladder while the blade
cuts below it. Wedges are banged into
the end and along the length as cutting
proceeds to prevent slumping. An oiler
has been fitted to drip on the saw tip.
Most slabs are cut to around 40–50mm.
Hardwoods, like the walnut shown here,
can be sliced thinner, while macrocarpa
lends itself to a chunkier cut. “This little
log is worth $1K milled,” says Dave. “It’s
shocking that timber like this is used for
firewood. People don’t realize its value.”
put into a walnut tree, the more fruit pine for sleepers for New Zealand Rail.
it would bear so they banged nails and It was all done by hand with two-man
even horseshoes into them. That’s why “I’ll only get about cross-cut saws in those days.”
sawmills won’t touch it.” two weeks out of His father, a bulldozing contractor
Nails aside, sharpening the teeth is a from the Taramakau, also loved his
tedious part of the job and the chains
a chain” wood. When he died two years ago,
have a limited life. “I have to sharpen Dave had a piece of 600-year-old rimu
the saw after every slab on a big cut. It he had heli-logged from the area made
takes me about two minutes with a hand into his urn box.
ÀOH ,·YH VKDUSHQHG VR PDQ\ , FRXOG GR In the blood Dave cut his teeth logging in Nelson
it with a blindfold,” he says. “The chain Dave, born in Greymouth, comes from a before taking to the air heli-logging.
gets hot and deteriorates quickly with IDPLO\RI:HVW&RDVWHUVZLWKDQDIÀQLW\ It was dangerous work and while
continuous cutting like this, so I’ll only for the forest: “My grandad started retrieving pine in the Motueka area, the
get about two weeks out of a chain.” milling in 1950 at Jacksons doing silver helicopter crashed and burned, killing

the pilot, Pete McColl. Dave, who was It proved so rewarding that he decided
lucky to have just got out of the machine, to turn his hand to it full-time and set
milled the timber for Pete’s headstone up Chainsaw Tree Milling New Zealand
and his plaque at the crash site. in 2016.
He then headed to the North Island
to do some native-timber contract work Interesting scrap timber
before being called up by a Hokitika- As well as milling private clients’ timber,
based company in 2004. he keeps his eye out for unwanted trees,
“I did all their sustainable heli-logging windfalls, and standing dead trees to
from Nelson Lakes up the Howard mill into slabs to sell. “DIY people love it,”
Valley through to Maruia.” In between KHVD\V:RRGGHVWLQHGIRUWKHÀUHZRRG
logging contracts and private tree heap is often the most interesting. “Logs
felling, Dave started dabbling in one-off with a bend in them make fantastic
chainsaw slab work about 12 years ago. natural bar leaners,” he says. “I cut

Drying out
Dave’s forest is full of stacks of timber,
drying naturally in the elements. The
drying time depends on the type of
wood and the thickness of the slabs —
the rough guide being a year per inch.
Dave recently milled 50 slabs from a
90-year-old walnut, timber that will
now sit for seven years before it can be
used. “Old timers on the Coast told me
to leave hardwood in running water for
12 months to flow the sap out,” says
Dave, but he hasn’t tried it.
Dave creates replica manuka mining trolleys using coal wagon wheels from abandoned
West Coast mines. They are constructed out of long-length manuka firewood and bolted
together to form sturdy decorative garden features.
10 out of two big pine logs that were rebuild,” he says. “One lady approached
otherwise worthless and sold them all me about a walnut tree the family had
to a Christchurch pub.” grown up with that had been wrecked in
Dave has also been called on by people the quakes. I milled it up and she was over Wood destined for the
who have lost trees or had to abandon the moon. She had platter boards made ¿UHZRRGKHDSLVRIWHQ
their properties after the Christchurch for their daughters as keepsakes and her
the most interesting
earthquakes. “I’ve done a few trees in the husband even got a 20-litre bucket of
red zone. People like to take something VDZGXVWRXWRILWWRVPRNHKLVÀVK,IWKDW·V
away with them and use it in their not sustainable I don’t know what is.”
Dave’s guide to cutting huge beams with a chainsaw!

Dave milled these huge 100-year-old
Douglas fir beams on a private property
in Geraldine, where they were used for an
outdoor entertainment area. At 9.5m long
and 400x400cm square, it was a massive
undertaking and one not possible for a
sawmill. “Your first cut is the most important,”
says Dave. “We had to get everything dead
level with string lines. We basically did it by
joining a whole heap of scaffolding planks
together. After we had taken off that first cut
we used the ladder.” He used his vertical saw
for the sides, again using string lines to mark
the right angles. “It took a day per beam and
we did three beams.”

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Lloyd Knowles: sawmilling
T
he smell of macrocarpa and
scream of saws greets visitors to
a family-run sawmill up a valley
behind Motueka where Lloyd Knowles “A lot of people around
specializes in making one-off timber here are doing their
SURGXFWVRIWHQZLWKLQWULFDWHSURÀOHVIRU
do-it-yourself builders, renovators, and
own building now,
furniture-makers. especially baches”
“We make a whole range of stuff, from
weatherboards to architraves, as well
as replica mouldings using different
SURÀOHV :H MXVW PDNH D SDWWHUQ WR ÀW property in the 1960s before turning to
whatever they want. ‘Negative detail’ tobacco farming. “He made the mill up
LVWKHÁDVKWHUPµVD\V/OR\GZKRUXQV from parts, starting with derelict steam-
the business with his wife, Diane. Most driven machines hitched to a tractor and
requests for bespoke work come from adding electric motors. The gorse grew
Golden Bay and Motueka. “A lot of up through it and you couldn’t even see
people around here are doing their own WKHVDZPLOOZKHQ,JRWWKHUHµKHVD\V
EXLOGLQJQRZHVSHFLDOO\EDFKHVµ /OR\G ZDV ZRUNLQJ DV D MRLQHU LQ
Lloyd’s father ran a small mill on the Motueka in the 1970s before hanging

Above: Lloyd makes all the knife steels by hand,
cutting new ones to specific profiles if they are
not already in his collection. It takes a good eye
and a fair bit of maths to replicate the negative
detail of samples to be copied. He has 200 little
patterns and drawers of curved knives and set-up
gauges in the workshop
up his hammer to resurrect the mill and

build a house. “I made all the windows
and cupboards before I left, then just
had to build a house to put them in
DQG KRSH WKH\ ÀWWHGµ VD\V WKH GUROO
sawmiller, who claims that he built the
house, where he and Diane raised their
family and their daughter now lives,
with a skill saw.
Fruit boxes
In 1985, he transformed an old lean-to
barn below the house into an operational
mill and from small beginnings grew
it into a boutique business that now
employs a full-time staff member as
well as the couple and their son.
“We started out making pallets for
WKH NLZLIUXLW LQGXVWU\µ VD\V /OR\G
´1H[W WKH\ ZDQWHG WUD\V /LWWOH ER[HV
out of thin bits of wood. One year I

Right: He fits his homemade knife steels
to the cylinders (you can see a couple to
the far left of the photo), which are then
attached to the machine and shape the
timber in one pass
From logs
to lumber
Technology may have changed but the
milling process remains much the same.
A sawyer uses a ‘head rig’ (or ‘head saw’)
to break the log into ‘cants’ (partially
processed logs with at least one cut
surface). The irregular surfaces are
trimmed, or edged, leaving four-sided
lumber, and the ends squared to length.
Lumber must be dried before use to
remove the natural moisture. It can be
stacked to dry naturally, a process that
can take several years, or kiln dried. Once
dry, the timber is planed to smooth the
surface and give a uniform width and
thickness, and any embellishments or
profiles can be worked.
“It can be a challenge.

It takes a lot of time to
set it all up and make
a few bits of timber”
made 44,000 of them. We got two or No job is too small but Lloyd admits
three years out of that before they went WRORVLQJDELWRIVOHHSRYHUÀGGO\MREV
to cardboard.” “It can be a challenge. It takes a lot of
Garden trellis was their next bread- time to set it all up and make a few bits
and-butter line. “We made miles of timber,” he says. “People restoring
and miles of that, then started doing old houses will bring in a sample and
tongue-and-groove with an old four- ask for so many this long and so many
sider. It’s a museum piece now,” he says. that long. We’ve just done four 27cm
“Once we got this high-speed machine, pieces of detail for a tile edging.”
we were away.” The Weinig four-sider
sawmilling moulder acts like a giant Hand-built belt sander
router, with moulding blades attached They keep a stock of dry timber stacked
WR F\OLQGHUV WR VKDSH WKH SURÀOHV D ELW and ready to use, including macrocarpa,
DW D WLPH /OR\G FXWV DQG ÀOHV DOO WKH poplar, pine, and lawson cypress,
blades, or knife steels, to shape by hand. as well as native beech and rimu. `

Above: Sharpening and ‘setting the teeth’ of the saw blades are
time-consuming. Lloyd uses both machine grinders and hand files
to sharpen the blades, and a spirit level-type device and gauge to
measure and adjust the angles of the teeth. If any teeth are out of
line, the saw will chew the wood. “I can get round a big blade in
about 10 minutes,” says Lloyd. The saw blades last about five years
if sharpened correctly, which essentially, over time, moves the teeth
around the circumference
Above right: Lloyd’s very-old-but-still-very-effective sanding belt
Right: All the Knowles’ machines are hooked up to extractors, which

suck the sawdust up chutes and into bins outside. “It’s handy having
a farm, because it can be a problem disposing of it,” says Lloyd, who
dumps it in pits, being careful to keep any treated sawdust separate.
It is also used for calf bedding by local farmers and compost by
gardeners

History
Before the invention of the sawmill,
boards were split (‘rived’) and planed or
sawn by two men with a two-handled
whipsaw. ‘Saddleblocks’, or ‘dogs’,
were used to hold the log in position
over a sawpit. It was exhausting work,
especially for the top sawyer, who had
to balance on the log, guide the saw,
and didn’t have the pitman’s advantage
of gravity.
Early sawmills adapted the whipsaw to
mechanical power, generally driven by
a waterwheel. A connecting rod known
as a ‘pitman arm’ (the origin of a term
now widely used) converted the circular
motion of the wheel to the back-and-
forth motion of the saw blade.
Circular-saw blades were invented
around the late 17th century. ‘Gangsaws’,
which had several parallel blades so that
a log could be reduced to boards in one
step, soon followed. Circular-saw blades
were prone to damage by overheating or
dirty logs, giving rise to a new technician,
the sawfiler, whose job was to set and
sharpen teeth.
Mills became highly mechanized
with the advent of steam power in
the 19th century, and further so with
electricity. Most aspects of sawmilling
are now computerized.
Right: Lloyd insists timber needs air to dry

correctly
Below: Many of the tools in this shed are
decades old - but still as reliable as the day
they were new
Most of it is plantation-grown or
windfall, though a lot of people bring in “Most of it came out
wood from their own properties to be of the ark. The whole
machined. Dryness can be an issue with site really needs to be
privately supplied wood. “People have
often stored it in sheds under plastic so
turned into a museum”
it isn’t dry enough. It’s got to have air,”
says Lloyd, who sometimes stacks wood
LQ WKH RIÀFH WR VSHHGGU\ WLPEHU ´,W·V original Cadillac gearbox. Lloyd reckons
my kiln,” he says. his hand-built belt sander, a “relic” in
The Knowles have built up an array leather and wood, does just as good a
of heavy-duty equipment over the job and is more reliable than its modern
years, much of it adapted from the early counterparts.
milling days. There’s nothing shiny in “Most of it came out of the ark,” says
this shed and barely a shred of plastic Lloyd. “The whole site really needs to be
in sight. The oldest saw still has its turned into a museum.”

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scale of the competition was amazing. It

ZDVQHUYHUDFNLQJµ
He says that he kept tension at bay by
focusing on the task at hand and keeping
in mind on the tips given to him by his
mentor, Mike Naus, who is the WorldSkills
aircraft maintenance deputy chief expert in
New Zealand.
“Mike was great — we had reviews about
how each day went and how I felt I was
tracking, which was really useful to get
some perspective. I’ve had so much support
from the staff of Air New Zealand all the
way through my apprenticeship — you’re
always under the pump at work but there’s
nothing quite like doing a job under the
eyes of judges,” he says laughing.
7KH \HDUROG IURP 6RXWK $XFNODQG
DOZD\VNQHZDQRIÀFHMREZDVQRWIRUKLP
and initially thought that he might train as
a car mechanic until he became fascinated
by complex aircraft systems. When he
left Sancta Maria College he worked as a
baggage loader at Air New Zealand for a
year before joining the Aviation Institute
and starting his apprenticeship in 2013.
Jarrod was among 13 other
Going for gold

1HZ =HDODQGHUV ZKR ÁHZ WR $EX 'KDEL
to compete against 1500 competitors from
76 countries in 51 skill tournaments at the
event. As well as the gold medal Jarrod
By Sarah Beresford was awarded Best in Nation for scoring the
highest points among all competitors from
A KIWI EXCELS IN A WORLD-CLASS New Zealand.
“New Zealanders really punched above
COMPETITION FOR TRADIES our weight in the competition. We weren’t
I
t’s enough of a buzz to have the skills believe he was so successful in the face of the underdogs but we don’t have the backing
you’ve developed as an apprentice such tough competition. and sponsorship that some of the teams
recognized nationally but to win “We had to compete in seven modules enjoy. For instance, France was sponsored
international plaudits launches the thrill over a period of four days. The modules by Adidas. There are international scouts
level into the stratosphere. all had allocated time frames of between that attend the event who focus on some
Aircraft engineer Jarrod Wood is familiar two to four hours. There were apprentices of the trades and are on the lookout for
with the excitement of having his skills from 16 countries competing in my promising new talent.”
acknowledged after winning both regional FDWHJRU\ LQ HYHU\WKLQJ IURP ÁLJKWFRQWURO -DUURGVD\VWKDWKHKDVQRZÀQLVKHGKLV
and national WorldSkills competitions for rigging to component changes and it was apprenticeship and his next goal is to share
aircraft maintenance. He crowned this really intense.” the knowledge he has gained with the next
achievement by winning the gold medal Jarrod says even the size of the venue competitor in the event, which is held every
LQ KLV ÀHOG DW WKH UHFHQW LQWHUQDWLRQDO and the number of spectators was daunting. two years.
WorldSkills competition in Abu Dhabi. “I have competed in the regional and “Competing in WorldSkills has increased
“It was a truly amazing experience,” the national WorldSkills competitions here P\ VNLOO OHYHO IROG DQG ,·P PXFK PRUH
Air New Zealand aircraft maintenance in New Zealand but the atmosphere FRQÀGHQW 2YHUVHDV LW LV ZHOO NQRZQ DQG
engineer says of attending the event. “I in Abu Dhabi was on another level. It’s HQMR\VDYHU\KLJKSURÀOH,Q1HZ=HDODQG
was blown away just to be there and wasn’t basically the Olympics for trades. The venue it’s sort of kept under wraps and it deserves
expecting to win, so that was just the icing was three to four times the size of the more recognition. WorldSkills offers so
on the cake.” ASB Showgrounds in Auckland and there many opportunities and has great potential
-DUURG VD\V WKDW KH VWLOO ÀQGV LW KDUG WR were more than 125,000 spectators so the so it deserves to be under the spotlight.”

C
ongratulations to Bryce Glifford I clearly missed the Health and Safety
who wins a Teng socket set with /HFWXUHEHIRUHP\EHWWHUWKÁHZRXW
this entry. This competition ran in to sunny Greece. (I have enough for a
the last issue of The Shed, issue #77 short novel should you need an article
“I am currently at home off work on what I learned)
sporting a broken leg due to falling out One photo here shows the dismantled
of my garage roof. I was obtaining Villiers two stroke engine which
some two stroke motorcycle wheels hopefully soon will look like the other
stored in the roof space above in early photo when its restored. Then it will
December. (I am not a happy camper, go into my 1954 Excelsior Roadmaster
the disruption to Christmas Holidays 197cc motorcycle that I am restoring.
and New Years etc has been far reaching The Teng Set 34 pc or the 30 pc set
to say the least). ZRXOG EH ÀQH VKRXOG , EH ZRUWK\ DV
I hit the concrete at 8.25m/sec, some of my gear is looking a bit ropey
when two seconds later the wheels in after 30 odd years working on bikes.
question fell the 2.4 m onto my already But preferably an AF set because the
crumpled pelvis and ankle while I was motorcycle in question was built not in
lying horizontal across my ladder. It was the metric age but in the imperial age.
Keystone Cops all over again. Many thanks, great issue this month
No cell phone to hand, no neighbours too.”
handy and no one home as everyone was Flattery always works with us Bryce!
overseas on holiday in Greece and Italy. We’ll be in touch soon to arrange delivery.

Letters
The winner of the Letter of the Month

ZLQVWKLVÀQH&KDQQHOORFN)DVWHQHUVHW
Letttheer
of
H
MONT
Jakob’s hut
Over last winter my eight-year-old he could still use it in his teens.
grandson and I built a hut for him in his Also we were limited in space to 2.4m
parents’ backyard. Before we started I wide by approximately 3m long. Channellock has put together
turned to two back issues of The Shed It was a joint effort, with him helping this fastener set, made in the US
magazine (August/September 2013 much of the time. There were many since 1886 by forging high-carbon
and April/May 2015) to get some good things that happened during steel. Tradesmen have enjoyed
guidance. I wish to acknowledge and the project, most important of all was the Channellock Blue grips for the
thank the contributors of the two TXDOLW\ WLPH VSHQW WRJHWKHU 7KH ÀQDO comfort of use and the undercut
articles (Build a Playhouse and Child’s result is worthwhile and he will be able tongue-and-groove design, which
won’t slip. The Permalock fastener
Play). Between them they started us off WREHQHÀWIURPLWIRUVRPHWLPHWRFRPH
eliminates nut-and-bolt failure, while
in the right direction. In the process he learnt many useful
the patented reinforcing edge on the
We thought that you might like to things that he will be able to use in the
channel minimizes stress breakage.
VHH VRPH SKRWRV RI WKH ÀQDO UHVXOW future. Sure, it was not safe for him to
The set includes models CH420G,
My grandson Jakob had a very good use all the equipment, such as power
CH426G, and CH440G (9.5 inches /
idea of what he wanted. Among the saws, but he learnt what they are used
240mm, 6.5 inches / 165mm, and
requirements [were that] it had to have for and the safety issues around them. 12 inches / 300mm) straight-jaw
a porch, windows that opened and Jakob learned how to use a battery- tongue-and-groove joint pliers.
closed, a table to work on, and a bunk. powered drill and drilled many holes for
The set is available from all plumbing
In place of the last item we installed a me to follow putting in the screws. He and engineering stores (RRP $120).
hammock, which is much more practical also learned about the hand tools, their
in the small space available. It has been names and their uses, and was able to Letters should be emailed to
assembled so that it can be taken apart use many of them on the project. The editor@theshedmag.co.nz, or posted
and reassembled somewhere else in the ÀQDOMREZDVWRKHOSZLWKWKHSDLQWLQJ to Editor, The Shed magazine,
future. The main issue for me was to get -DNREOHDUQHGDOLWWOHDERXWÀUVWDLG PO Box 46,020, Herne Bay,
Auckland 1147.
the height right – not too high for an during the project. One day he grazed
eight-year-old but still high enough that RQHRIKLVÀQJHUVDQGLWEOHGDOLWWOHELW
He came to me and said, “Grandad I’ve sticking plaster from his parents. On
FXWP\ÀQJHUµ,KDGDORRNDWLWDQG the last day of the project I slipped with
said, “It will be alright, just suck up the the screwdriver and it shot into my
EORRGLWZLOOEHÀQHDQGFDUU\RQµ+H ÀQJHU,WZDVRQHRIWKRVHVKDOORZFXWV
GLGQRWDFFHSWP\ÀUVWDLGDVVHVVPHQW that really bleed a lot, the blood was
and treatment. He said “I don’t like GULSSLQJRIIP\ÀQJHULQVHFRQGV0\
WKHWDVWHRIEORRGµ,DVNHGKLPLIKDG grandson said, “Never mind, Grandad,
tasted blood before. The answer was be tough, just suck up the blood and
in the negative. I suggested that he FDUU\RQµ
toughened up a bit. His response was:
´,·PQRWWRXJKOLNH\RX*UDQGDGµDQG Tom Nimmo
he rushed off to get some TLC and Nelson

The New Era of
Rainwater Harvesting
Drawing water in, keeping leaves out
The new Marley Curve™ combines sleek, sophisticated design

with innovative filtering technology to draw water in, while
keeping leaves and debris out. The Marley Curve™ blends
seamlessly into your downpipe system and helps prevent
contaminants entering your water tank or stormwater system.
Can capture over 99% of water with a clean screen*
Cleaner water into your tank improves water quality and

reduces maintenance
Reduces chance of your drains blocking
Quick release upper body for easy maintenance
Water when you need it
The new Marley Twist®, with an easy twist on-off function,

turns your downpipe into a free source of water. Great for
your garden, topping up swimming pools and emergency
water supplies.
Provides access to free rainwater from your downpipes
Can fill a 300 litre tank in an hour*
Positive impact on the environment through reduced mains

water usage
Direct connection to standard hose fittings
Curve™ and Twist® are available in a range of colours
White Grey Friars® Ironsand® Black Copper Titanium

(Metallic) (Metallic)
Actual colours may vary slightly from those shown.
* See Marley.co.nz for details.

Rainwater harvesting

rain,,
rain,
come
o e
again
PRESERVING OUR MOST PRECIOUS
RESOURCE PRESENTS SOME DISTINCT
CHALLENGES
By Jude Woodside
Photographs: Jude Woodside
W
ater is becoming political; it Mandatory harvesting
won’t be long till we are taxed New Zealand is blessed with ample
for it or paying for how much we supplies of water, in the main, but even
use. Climate change will only exacerbate we can suffer from seasonal shortages
this as droughts become more frequent. in regions according to the weather.
It will soon be incumbent on all of The east coast of both islands has quite
us to preserve and reuse water. That VLJQLÀFDQWO\ UHGXFHG UDLQIDOO FRPSDUHG
is already the case in Australia where with the west coast or central regions.
many states insist that new homes have In areas where the water supply is
water tanks, and grey-water tanks are problematic or will require large
often mandatory too. In New Zealand investment in infrastructure to secure
around 10 per cent of the population in the future, some district councils
relies on tank water, mostly rural or such as Kapiti have passed by-laws so
coastal properties. Others use tank water that all new dwellings from 2008 on
to supplement their town supply for must have a 10,000-litre rain water
gardening and other purposes especially tank or a 4000-litre rain water tank
where usage is monitored and charged. and a grey-water diversion system. `

The case for
mandatory water
harvesting is
gathering momentum
Left: The rainhead fitting with both

screens fitted
Below left: The stuff you don’t really

want in your tank
In parts of Australia it is mandatory fairly ludicrous to be using treated potable the garden, and cleaning the car, etc.
to have water-storage tanks in any ZDWHU IRU ÁXVKLQJ WKH WRLOHW ,Q IDFW RQO\ — tasks which could just as easily be
new building consent and grey-water a small proportion of our water supply accomplished with harvested water.
diversion is encouraged too. is used for purposes that require potable ,Q IDFW ÁXVKLQJ WKH WRLOHW FRXOG UHXVH
The case for mandatory water water: drinking and personal washing — grey water from the shower or washing
harvesting is gathering momentum. In ZHGULQNRUFRRNZLWKRQO\ÀYHSHUFHQW machine, but that’s another story.
an age when we are urged to conserve of our water. The rest goes on showering,
resources as much as possible it seems ZDVKLQJFORWKHVÁXVKLQJWRLOHWVZDWHULQJ Gather 500 litres a day
Depending on where you live in
New Zealand you can collect around
180,000 litres per year or an average of
500 litres a day for an average 150m2
house, where rainfall is around 1200mm
annually as it is in Auckland. Around
80–90 per cent of this can be collected,
with the rest being lost to evaporation or
spillage. In an area that charges for water
consumption — both supply and waste,
as in Auckland — it makes good sense to
take advantage of the free stuff and use
it for things that can offset the metered
usage such as watering the garden or
cleaning the car.
Installing a 35,000-litre tank that
is sited on the ground on a suitable
substrate does not generally require a
permit or resource consent although it
pays to check with your local authority.
Bear in mind that that 35,000-litre tank

Above: Attaching a rainhead
Far right: Fitting a downpipe first-flush
diverter
holds 35,000kg (35 tonnes) of water

so try to position it on a dry substrate
in an area where it will not sink into
WKH JURXQG ZLWK WKH ÀUVW GHFHQW UDLQ
in winter.
Cleanliness
:KHUH ZDWHU LV UHWLFXODWHG LQ UHJLRQDO
WRZQVDQGLQGHHGLQVRPHFLWLHVLWVSXULW\
is not always guaranteed, as the residents WKH FRXQWU\ RYHU ÀYH \HDUV XS WR
RI +DYHORFN 1RUWK UHFHQWO\ GLVFRYHUHG by Massey University showed at least
7KHVDPHFDQEHVDLGRIZDWHUKDUYHVWHG KDOI RI WKH VDPSOHV H[FHHGHG PLQLPDO
IURP \RXU URRI %XW LI WKH FOHDQOLQHVV RI DFFHSWDEOH OHYHOV IRU FRQWDPLQDWLRQ
UHWLFXODWHG VXSSO\ LV VXVSHFW WKDW VWXII DQG PRUH WKDQ SHU FHQW RI VDPSOHV
washing off your roof is even worse. Too VKRZHG HYLGHQFH RI KHDY\ IDHFDO
RIWHQ ZH DUH VLPSO\ FUHDWLQJ D WDQN RI FRQWDPLQDWLRQ7KDWVWXG\ZDVFRQGXFWHG
SDWKRJHQVWKDWZHWKHQEOLWKHO\FRQVXPH E\ WKH 5RRI :DWHU 5HVHDUFK &HQWUH DW
$ VXUYH\ RI WDQNV WDNHQ DFURVV Massey University in Wellington headed

by microbiologist Stan Abbott. He is an who became ill due to contaminated Top: (Left) Dripper washers. These regulate
how quickly the diverter will empty. (Right)
enthusiastic supporter of urban water water were reported to health authorities. An internal filter to prevent the dripper from
harvesting, both to offset the waste of Most of the disease-causing pathogens getting blocked
potable supplies and for emergency come from the roof and are delivered in Above: The washer fitted to the end cap
situations. WKH ÀUVW ÁXVK RI UDLQ WKDW ZDVKHV DOO WKH
Of course those who have lived with recent bird and small-mammal faeces and
tank water for years will claim that “it decaying plant material in the gutters
never hurt me” and that may well be and microorganisms that are present in
true but it is unlikely be true for your road dust on the roof into the tank. Bird
visitors. You may indeed be immune to faeces carry a variety of microorganisms
some of the pathogens in your tank, but including the ubiquitous E. coli but they
not all — a recent Food Safety Authority can also host Salmonella, Campylobacter,
VWXG\ VKRZHG WKDW WKHUH LV VLJQLÀFDQW and Cryptosporidium. Most of these thrive
under-reporting of illness related to tank in warm tank water but can survive even
water. In fact less than a third of people in cold weather. `

Rainwater Level Running Low?
E W
N ODUCT
PR
FULL FLOW VALVE 1275 l/min @ 12bar
Why do I Need a
Rain Relief Valve?
If the tanks rain water level drops
below minimum, the Rapid~Flo valve
opens to supplement the tanks water
from an alternative source such as the
mains water supply. However it will
only increase the water level by either
50 or 100mm.
Prevents Dry Tank Syndrome

Supplement your rainwater
tank from an alternative
water supply
Harvest rainwater and only
pump when you need to
Scan to find your local stockist

www.hansenproducts.co.nz/stockists.htm
Above: Showing how the ball valve works
blocking the diverter
Left: Fitting the ball into

the diverter
XQWLO LW HYHQWXDOO\ EORFNV WKH LQWDNH DQG

Primary treatment OHWVWKHUHPDLQLQJZDWHUUXQWRWKHWDQN
2IFRXUVH\RXFDQÀOWHUDQGWUHDWWKHZDWHU Of course those who 3ULRUWRWKHÀUVWÁXVKGLYHUWHULWLVZLVHWR
DIWHUKDUYHVWEXWPRVWRIWKHVHSDWKRJHQV have lived with tank LQFOXGHDOHDIVFUHHQWKDWHQVXUHVWKDWWKH
FDQ EH VLPSO\ DYRLGHG ZLWK VRPH VLPSOH water for years will GLYHUWHUGRHVQRWJHWFORJJHGZLWKOHDYHV
SUHFDXWLRQV 7KH PRVW REYLRXV VKRXOG EH RURWKHUUXEELVK7KHGLYHUWHUZLOOVORZO\
DÀUVWÁXVKGLYHUWHUDWDQNWKDWFROOHFWVRU
claim that “it never UHOHDVHWKHZDWHURULWFDQEHGUDZQRIIIRU
GLYHUWVWKHÀUVWIHZOLWUHVIURPWKHURRIDQG hurt me” and that ZDWHULQJWKHJDUGHQ
DOORZV WKLV WR GUDLQ DZD\ 7KH ÀUVW ÁXVK may well be true but
IURPUDLQZLOOFRQWDLQDOOWKHDFFXPXODWHG
it is unlikely be true
Tank fittings
URDGGXVWDQGGULHGELUGIDHFHVWKDWKDYH :LWKLQ WKH WDQN SDWKRJHQV DQG
VHWWOHGRQ\RXUURRIVLQFHWKHODVWUDLQ,Q for your visitors PLFURRUJDQLVPV ZLOO JUDGXDOO\ IDOO WR
IDFWWKH0DVVH\8QLYHUVLW\VWXG\IRXQGWKH WKHERWWRPDVZLOODQ\DOJDHDQGRWKHU
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HIIHFWLYH PHWKRG RI PDLQWDLQLQJ JRRG D F\OLQGHU WKDW FDQ FRQWDLQ EHWZHHQ WKH WDQN LV W\SLFDOO\ DQ DQDHURELF OD\HU
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0RVWÀUVWÁXVKGLYHUWHUVZRUNE\KDYLQJ LQ WKH XQLW WKDW ULVHV DV WKH GLYHUWHU ÀOOV :DWHU HQWHULQJ WKH WDQN VKRXOG GR VR

The completed downpipe diverter
Above: Cutting 300mm pipe for the

Typical water standalone diverter
usage in the home

Below: Bevelling the cut end of the pipe
Usage Litres
Right: Gluing on the end cap
Cleaning teeth 5
Bath 100-200
Shower 30-100
Toilet (Half Flush) 6
Garden Hose (On Full) 50/minute
Dishwasher 25
Washing Machine (Top 100-200
Loading)
Washing Machine (Front 70-85
Loading)
Dripping tap 60,000/ year

Above: Adding the first stainless-steel filter …
Left: … and the second plastic filter
In fact the
Massey University
study found the
¿UVWÀXVKGLYHUWHU
to be the single most
H̆HFWLYHPHWKRGRI
maintaining good
water quality
through a calmed inlet set above the base the cleaner water at the top. When the make the business of securing your water
that prevents the incoming stream from water level drops and uncovers the hole supply straightforward.)
stirring up this material and making the again and air enters the siphon it will
water turbid. The output of the tank is automatically stop to avoid the entire Rainhead
ideally taken from the water at the top tank being emptied. Assuming your guttering is installed
of the tank where it should be relatively FRUUHFWO\ ZLWK DGHTXDWH IDOO ÀUVW
clear and clean. This is often achieved Getting started calculate the amount of water that needs
ZLWK D ÁRDWLQJ LQWDNH WKDW HQVXUHV WKH If you are setting up your rainwater- WR EH GLYHUWHG WR WKH ÀUVWÁXVK GLYHUWHU
output is taken a controlled distance from KDUYHVWLQJ V\VWHP IRU WKH ÀUVW WLPH RU (see First-Flush Calculations panel).
the top of the water column. thinking of modifying your present There are two options — you can either
A siphon is generally used to spill water arrangement in light of what we’ve just ÁXVKLQWRDGRZQSLSHFROOHFWRUIURPWKH
when the tank is over-full. This is a pipe discussed, here’s how to do it. gutter or into a separate freestanding
with a bend that runs from the base of (This is a revision of material we published cylinder, ideally near the tank. The latter
the tank’s interior to the outside. The top in 2008 in a similar article. It utilizes is useful for larger roof spaces and larger
of the siphon bend has a hole. When the mainly Marley products. David Oliver, ÁXVKHVHVSHFLDOO\IRUDUHDVQHDUWKHFRDVW
water level covers the hole, the siphon the business development manager with or where birds might be a problem — do
starts automatically and will tend to Marley at the time, presented it for us. you have a pigeon fancier as a neighbour?
suck up debris off the base and from the Marley makes a comprehensive collection You must install a rainhead with a leaf
DQDHURELF OD\HU ÀUVW UDWKHU WKDQ VSLOOLQJ of rainwater-harvesting accessories that screen; this needs to be installed as high

as possible under the eaves. It’s the
point where the gutters meet. The mesh
on the leaf screen is less than 1mm to
stop mosquitos and insects getting
though into the tank. There is also a
wider secondary mesh to collect leaves
DQGRWKHUODUJHUGHEULVEHIRUHWKHÀQH
ÀOWHURIWKHUDLQKHDG7KHPRXWKRIWKH Fitting the bracket to hold the diverter to a post
rainhead is intentionally wide to cope
with a sudden dump of rain in a storm.
There are other leaf screens, including First flush calculator
the Marley curve, but the rainhead
KDV WKH PRVW FRPSUHKHQVLYH ÀOWHULQJ To calculate the safe amount of water to divert from the roof, Marley
recommends the following formula
It pays to have some kind of debris-
ÀOWHULQJ V\VWHP LQ \RXU JXWWHU WRR Roof area x pollution factor= litres to divert
either one of the many gutter screens The pollution factor varies with the environment:
RUEULVWOHÀOWHUVWRHOLPLQDWHPRVWRIWKH • Minimal Pollution (open field, no trees , no bird droppings and a clean
debris at source. environment) Use pollution factor 0.5
• Substantial Pollution (leaves and debris, bird droppings, insect matter).
First-flush diverter Use pollution factor 2.0
,I \RX ZLVK WR PDNH \RXU ÀUVWÁXVK So for a house with a roof area of 120 sq metres in a low pollution environment
diverter in the downpipe from the would require 120 x 0.5= 60 litres diverted.
UDLQKHDG À[ D 7VKDSHG FRQQHFWRU DW From the table you can work out the length of pipe required for the first flush
the outlet of the rainhead to the diverter. diverter.
The diverter chamber can run off this if
it is a small diverter. Alternatively, run Pipe volumes
the outlet of the rainhead to the tank
Product Length of chamber Volume in litres
and install the diverter to a separate post
90mm First flush diverter 1 metre 5.7 litres
closer to the tank. The diverter itself
2 metres 11.4 litres
FRQWDLQVDSODVWLFEDOOWKDWÁRDWVXSZDUGV
DV WKH GLYHUWHU ÀOOV XQWLO LW HYHQWXDOO\ 3 metres 17.1 litres
blocks the inlet. As the diverter slowly 300mm First flush diverter 1 metre
leaks it will, from time to time, need to 1.5 metres 112 litres
EHUHÀOOHGZLWKWKHUXQRIIIURPWKHURRI 2 metres 147 litres
but this will only be a very small part of 3 metres 218 litres
WKHÁRZ`

Attaching the first-flush diverter
The diverter tank empties via a drip DSRVWRUDZDOO³WKHWDQNZLOOKDYHWR

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considering adding
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the output too
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Rainhead and Leaf Screen
Tank Breather
First Flush Diverter
Floating Outlet
Tank Siphon
Calmed inlet
gold standard is ultraviolet tank-water

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Cleaning or painting
,I \RX DUH GRLQJ URRI LPSURYHPHQWV
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A floating outlet. Note how the ball keeps the Attaching a hose to the outlet — the
URRI GR UHPHPEHU WR GLVFRQQHFW WKH outlet below the surface but close to the top of wastewater can be used on the garden
URRIFRQQHFWLRQWRWKHWDQNÀUVW the water column

INNOVATIVE WATER
HARVESTING PRODUCTS
DON’T GET CAUGHT OUT

Supplementing your water supply by harvesting
nature’s reserves can really save on water costs,
but in those drier months it can be a struggle
to keep anything in reserve. The Hansen
5DSLGÁR5DLQ5HOLHI9DOYHLV\RXULQVXUDQFH
against an empty tank. Designed to supplement
your rainwater tank by 50 or 100mm from an
alternative source when your water level gets too
low, it will ensure that you always have water on
hand, but also allows enough space in your tank
in case rain is on the way.
Visit www.hansenproducts.co.nz for your local
stockist and more info.
SWITCHING UP The Rainsaver MK4E, the company’s premium water-

If you’re keen to reduce your water usage by making the harvesting system, is ideal for large homes and commercial
most of nature’s generous supply, you may want to consider DSSOLFDWLRQVXVLQJDWDQNEDVHGÁRDWIRUSRVLWLYHVZLWFKLQJ
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Racing motorcycles
Art of
En g i n e e r i n g
CHRIS GORDON USES SKILL AND ARTISTRY
TO MAKE RACING MOTORCYCLES
IN HIS SHED
By Ritchie Wilson
Photographs: Juliet Nicholls

Chris doesn’t race bikes himself,
he enjoys building them
C
hris Gordon has been devoted to the ` Chris has also from a very early age made
internal combustion engine since Milling machine things: models, an electric bicycle, an electric
his earliest days when his next-door JRNDUWDÀEUHJODVVURDGUHJLVWHUHGVFUDWFK
neighbour was a motor mechanic. built car, and a 500cc V8-powered Grand Prix
At 14 he was a crew member for racing bike. He has a minimalist approach to
Ron Collett, who successfully ran a tools and equipment, but to make the racer’s
Top Eliminator class dragster at strips V8 engine he had to buy and master a small
throughout New Zealand. His Chris Gordon lathe and a serious large and highly capable
Racing Team won the 1998/’99 125cc milling machine. The alternative would have
New Zealand Road Racing Championship, been to get the machining and development
with well-known rider Dennis Charlett done professionally. Chris calculates that
riding a Honda RS125 that Chris owned this would have involved thousands of
and prepared. Chris and his team ran the hours of very expensive machine time —
bike in the 125cc class at the Australian say, 3000-plus hours at $100 per hour.
MotoGP at Phillip Island in 1999. ` That’s a lot of money.
One of the many jigs Chris made. In this case,

for the machining of the V8 racer’s crankcase
This is a Bridgeport-type mill made by

Luxcut, and it has a very useful digital
readout that allows much improved
resolution and hence more dependable
operation. Chris has used the machine
to produce parts for his bikes and the
very many gigs and mounts needed
when undertaking precision machining. The crankcase patterns for the V8 engine

Chris assembling the mould for the V8 racer’s glass-reinforced-plastic (GRP) (fibreglass) petrol tank
The 11 component pieces of the

The V8 racer’s fabricated GRP airbox The GRP body of the V8 racer
petrol tank mould
Chris is outstandingly well organized gears is arranged so that the combustion

and his workshop is a model of thoughtful impulses don’t coincide, making the
“I can make a mess,
planning. Partially this is a result of his engine run smoother.
racing background — you need to be able but I can’t work in Having made an engine, the next step
to access the necessary gear immediately a mess” was to make a bike for it to power. This
at the track and there is no place for not- required more work than Chris is happy
QHHGHGVWXII,WLVDOVRDUHÁHFWLRQRIKLV cylinder engines. The donor in-line-four WR UHFDOO EXW WKH LPPDFXODWH ÀEUHJODVV
practical approach: “I can make a mess, motors chosen were Kawasaki ZXR250s, SHWURO WDQN DQG IDLULQJV UHÁHFW KLV VNLOO
but I can’t work in a mess.” which can rev to 20,000 rpm, complete and painstaking approach.
to their crankshafts. These were bolted Chris doesn’t race motorcycles himself
Development of the to castings, which Chris made the and so would have had to let someone
V8 racer patterns and moulds for and which he else compete on the bike. This brought
Chris has an ongoing interest in the use machined. The original sump is retained the issue of his personal liability should
of multiple engines in a bike and came at the bottom of the engine. Gears at an accident occur. The inevitable
up with the idea of making a 500cc the end of each crankshaft drive the blowback from an accident involving a
V8 engine by mating two 250cc four- common clutch. The meshing of these machine that he made the vast majority

The artist and his work
of was not something he was prepared fastest form of racing was on the board-
to contemplate. So the racer has track racers that competed on banked,
never raced. oval, wooden motordromes. Chris would like
For his next project Chris decided that to have been born
something much slower would have Board-track racer
fewer legal risks. A friend was building The only part of Chris’ board-track
in 1880 so that he
a replica of a 1920s board-track racer racer that dates from the early part of would have been
and this appealed as something that last century, is the JAP crankcase and able to produce
could be built from readily available crankshaft. JAP engines were made by
bikes at the dawn of
PDWHULDOV EXW ZRXOG EH D VLJQLÀFDQW JA Prestwich Ltd in England from 1895
technical challenge. to 1963. The rest is new, purchased motorcycle racing
Chris would like to have been born in locally and online.
1880 so that he would have been able to The wheels and tyres are new and are
produce bikes at the dawn of motorcycle the most expensive parts of the racer.
Frame brackets machined from the
racing, before World War I, when the They were imported from America, solid and the several pieces TIG welded
together
Caption here...

The workshop
The wooden pattern for the head of the

board-track racer’s engine (left) and an
unfinished cast iron head (right)
The reproduction racing number was

made from an old biscuit tin. The rods
controlling the throttle can also be
seen
The neatness and organization of Chris’s east side has his drawing table with the
workshop’s reflects his no-nonsense double door behind it.
approach to things mechanical. He has His quick-release vice — a boon when
also extensively worked in fibreglass, working alone — tube bender, and racing
which is unrivalled in messiness. As a toolbox are on the bench, with a tool
result his machine tools are carefully board above. A Rolls-Royce Merlin engine
shrouded in cloth covers and most of part is, perhaps, a clue as to Chris’s
his gear is safely stored in cupboards. next project.
Surfaces are regularly cleaned. The only Chris would like to thank the
workshop I have seen that was cleaner New Zealand Electricity Department
was the Vespa repair depot in Hanoi, and its world-class tutors for giving him
Vietnam, which could have served as a a comprehensive technical education
hospital operating theatre. while paying him. He was taught skills
He has a metal-covered bench running and, even more important, attitudes that
the length of the south side of his have allowed him not only to earn a good
workshop. Floor-to-ceiling cupboards living and compete at the highest level in
are on the west side; his lathe, milling motorcycle racing but also to complete
machine, grinder, door, fire extinguisher, projects that are equal parts engineering
and phone are on the north side. The and art.
where a genuine Harley-Davidson

Board Track Racer can fetch more than
$200K. Professionally made replicas are
available in the US from $27K.
Chris started with old photographs of
racers and, taking the wheels as a guide,
scaled the images up to arrive at the
dimensions of his machine.
The frame is constructed of seamless
mild-steel tubing brazed into bracketry
made by Chris from solid steel. First,
the pieces were turned to size on the
lathe, then notched on the mill, then
WHPSRUDULO\EROWHGWRJHWKHUDQGÀQDOO\
TIG welded together.
The eye-catching handlebars were

bent on the tube bender that Chris
constructed when making the V8 bike
and incorporate an ingenious throttle
mechanism using rods. As the handlebars
are turned, a sliding section stops the
throttle setting from changing.
The engine is based on a 1908 250cc
JAP crankcase and crankshaft; a VW
Beetle cylinder and piston; and a
Chinese-made connecting rod, which is
a copy of a very early Harley-Davidson
one. Chris designed the head, with its
exposed valve gear and four valves.
It was cast by CanCast in Timaru, and
machined by Chris. The valves and
springs are Honda copies, the rockers
DUH PRGLÀHG /LIDQ DQG WKH SXVKURGV
have been fabricated from silver-steel
shafting. He is at a loss to understand
why the valve gear was exposed on
the original racers, as the weight of
an effective, oil-tight cover would be
minimal. The dusty environment of
the board tracks would have promoted
rapid wear. His best guess is that it was
The finished head and the exposed valve fashionable.
gear and pushrods
Is it real or is it a copy?
,ÀUVWVDZ&KULV·UHSOLFDERDUGWUDFNUDFHU
Tube bender DW WKLV \HDU·V 1HZ %ULJKWRQ EHDFK UDFH
where it was surrounded by an admiring
crowd, despite the presence of literally
The 28mm diameter chromoly tubing
hundreds of fascinating two-wheelers,
used in Chris’s V8 bike wasn’t able to
and a smattering of very desirable four-
be bent commercially in New Zealand
wheeled devices.
so he had to build his own bender. The
Even very knowledgeable observers
mandrels that sit inside the tube as it is
were unsure if the bike was the real
bent, stopping it from collapsing, were
thing or a copy. The most discussed
purchased from the US. Chris turned the
DVSHFW RI WKH UHSOLFD ZDV WKH ÁDZOHVVO\
formers, which the tube is rolled around,
aged patina of the steel frame, which
from aluminium plate. The holders for
was gratifying to Chris because he had
the formers were very nicely laser-cut
gone to extraordinary lengths to achieve
from steel plate by a local Pegasus Bay
WKHFRUUHFWORRNWRWKHELNH·VÀQLVK
company, and the holes for attaching
The frame tubes were sanded,
bolts machined on the Luxcut mill.
painted, assembled, then the visible
A bender requires more than formers
paint was sanded off, a chlorine solution
and mandrels though. It needs grunt.
lightly sprayed on and left to oxidize the
The first version was horizontal and
surface of the steel. When dry, the tubes
electric powered. It could not bend the
were wiped with an oil-soaked rag. The
tube at all. Several more versions were The fourth version has a large hydraulic
UHVXOWLQJÀQLVKLVH[DFWO\ZKDW\RXZRXOG
constructed — all proved inadequate. It jack pushing on long and strong levers
expect to see on a hard-used racing
wasn’t until Chris saw a photograph of a to provide a more-than-adequate
machine after more than a century had
large tube bender in a racing motorcycle– bending force. The jack operates best
passed. Anyone working on it would see
building manual that he fully appreciated when upright, so the bending is in the
WKHRULJLQDOSDLQWÀQLVKZKHQWKHIUDPH
the amount of force needed. vertical plane.
was disassembled. `

The Gordon GRP city car
After converting a motorcycle to run principles and its shape reflects not overhead camshaft (SOHC) twin
on electricity so he could get around only the trends of the late ’70s (think that could provide enough power to
the huge thermal power station he Austin Princess), but also the futuristic attain a top speed of over 50kph. The
worked at, a very young Chris Gordon designs of other electric vehicles drive from the engine to the short
decided to make an electric car. Like of the time. The interior finish is of driveshaft is by chain.
most makers of one-off cars, he made a similar standard to a production When the car was completed all Chris
the body out of fibreglass and used vehicle of the time. had to do to make it road legal was
the running gear from a donor car — The chassis is made from steel tube to take it along to the Ministry of
in this case a Triumph Herald. brazed together, and the wheels, Transport (MOT) testing station and
The GRP is up to 5mm thick, with a hubs, brakes, steering, and differential obtain a warrant of fitness, which it
central layer of core mat and includes are all from the small Triumph. still proudly wears.
the metal front-window surround The electric power option was killed The maker’s name at the rear was
from a Hino Contessa. The windscreen off by the weight of the lead-acid made from brass strip. The letters were
is (of course) from the same car. batteries needed, so a motorcycle shaped using hacksaw and files. The
The other windows are made from engine and gearbox were used logo combines Chris’s initials, C and G,
specially made Pilkingtons toughened instead. The unit chosen was a Honda with an arrow and was designed by
glass. The car was designed from first CB360 — a 356cc two-valve single him when he was at school.

Right: The board-track racer on a section
of reproduction board track. Note the
post-earthquake vertical support
Motordromes
Year opened Speedway Length Racing surface

1907 Brooklands, England 4.4km Concrete
1909 Indianapolis, US 4km Bricks
1910 Los Angeles, US 1.6km Wood
1929 Western Springs, Auckland 0.4km Mildly banked clay
1949 Aranui, Christchurch 0.4km Gas-works cinders
The mock tool-roll attached to the Some motordromes used 100x50mm

vintage leather saddle is turned from boards on the edge, and others were
wood recycled from a hardwood The dangers of racing 300x25mm. The amount of banking on
pallet. It contains the battery and the these machines the turns varied from 30° to more than
electronics of the ignition system, which 60°. The spectators sat at the top of the
were numerous
were purchased online. track, looking down on the racing, and
The drive from engine to rear wheel is were in great danger — competitors
by belt. The belt, manufactured for the losing control and sliding over the top
emergency repair of industrial drive belts, Motordromes would land in the crowd. Deaths were
is made from rectangles of polyurethane The dangers of racing these machines at a regular occurrence. At one race, four
riveted together, originally bright orange the motordromes were numerous. The young boys were killed when a riderless
coloured. It drives a period-correct large speeds were high (well over 100mph bike struck their heads as they leaned
pulley, also made from recycled pallet [161kph]), tyres were outstandingly out over the edge of the track.
wood, which is attached to the rear wheel unreliable, safety equipment consisted The popular name for the tracks was
by brass plates. The large diameter of the of goggles and a thick jumper, brakes ‘murder-dromes’. In America from the
driven pulley gives a high gearing, which were non-existent, and the surface could end of the 1920s, motorcycle racing
means the slow-revving engines of the be slippery with oil from the total-loss increasingly took place on dirt tracks
1910s could power the racers around the oiling systems or break up into holes and which were not only safer but also didn’t
banked wooden tracks at lethal speeds. nightmarish splinters. If you went too need to be extensively rebuilt every few
The bike has no brakes; only one gear; fast you could slide off the upper edge years. The Indianapolis banked oval,
but, unlike an original example, does of the banking to your doom — hence dating from 1909, has survived because
have a clutch. This is a copy of the clutch the expression ‘over the top’. There was it was made of brick. Brooklands in
from the celebrated Honda GY6 scooter, probably also an expression for being England, opening in 1907, was concrete
which is now produced in China in vast impaled by long splinters of wood from and it only closed when World War II
numbers, so parts are remarkably cheap. the track, but it hasn’t survived. broke out in 1939.

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Bow making
take
aim
THEY SAY YOU NEED TO
MAKE AT LEAST THREE BOWS
BEFORE YOU CAN MAKE A
DECENT ONE. RAF NATHAN
SHOWS HOW TO MAKE YOUR
FIRST ONE
By Raf Nathan
Photographs: Raf Nathan

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3 4 5
Plane the edge above the shoulder square
and parallel (Steps 2 and 3), and then
use a marking gauge to mark out the
shoulder (Step 4). Next, bandsaw out the
shoulder (Step 5).
The shoulders need to be as perfectly
level as possible and square to the faces.
To achieve all this you can work quietly
with a saw and chisel, or use a power tool
and a jig. Steps 6 and 7 show a shop-made
jig used to cut the shoulders with a router.
The arrow cutaway consists of a level
face that ends with a lip that continues
up in a sweep. The level face can also be
made with a jig and router as in Steps 8
and 9. The jig holds the router level and
makes a clean arrow cutaway. A ‘bowl 6
FXWWHU· D ÁDWERWWRP ELW ZLWK UDGLXVHG
corners) was used to rout this (Step 10). shapes were cut with a metal router. The
Rout down deep enough so that 18mm holes for the four square-drive screws were
thickness of wood remains. This should drilled and countersunk, and a sink with
then position the arrow shaft central to $QLQÀDWDEOHVDQGLQJ an 82-degree angle was used to ensure a
the string. The sweep that continues up EREELQLVDEVROXWHO\ WLJKWÀWZLWKWKHVFUHZKHDGV
allows you to sight the arrow when it Set your drill press to allow the screw
LQYDOXDEOHIRUWKLV
is mounted. heads to protrude slightly; they will sand
W\SHRIZRUNEXWQRW EDFN ÁXVK WR WKH SODWHV ODWHU +ROG WKH
Shaping HVVHQWLDO²MXVWDORW brass plates in position and mark out the
Now begins the actual shaping of the shape with a scriber. A laminate trimmer
IDVWHU
riser. This requires sanders, chisels, ZLWKDÁDWERWWRPELWFDQUHPRYHPRVWRI
spokeshaves, and patience. Step 11 shows the waste and, important, keep the surface
a belt sander reversed and the front drum ÁDWDQGOHYHO%HIRUHURXWLQJVHWWKHFXWWHU
being used to shape the hand grip. Using can be drilled. The holes need to be depth to the thickness of the brass. Pre-
a rounding-over bit in the router and exactly centred. Mark a centre line on GULOO WKH KROHV DQG ÀW VWHHO VFUHZV ÀUVW
running this over some of the edges can the shoulder, then hold the limbs in then remove them and replace with
speed things up. A spokeshave is of great place and mark where the holes need to brass screws.
YDOXHIRUUHÀQLQJOLQHVDVLVDVFUDSHU$Q be. In this case a horizontal mortising The hard walnut can break soft brass
LQÁDWDEOH VDQGLQJ EREELQ LV DEVROXWHO\ table was used for the drilling with a screws and removing broken screws is a
invaluable for this type of work, but not 9.5mm (3/8-inch) bit. hassle. Without the use of specially made
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starting hand sanding. Use 80-grit paper limbs parallel to the riser. The brassware the riser at 38mm (1½-inch) thickness so
followed by 100 and 120 grit. (Step 12) was prepared by a local engineer. WKDW WKH OLPEV ZHUH ÁXVK ZLWK WKH VLGHV
At this stage the holes for the limbs He was presented with a drawing and the Small shaped pieces of wood could then

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Welding
A NEW TROLLEY GIVES

A BARBECUE A FRESH LEASE OF LIFE
By Jude Woodside
Photographs: Samantha Woodside and Jude Woodside
I
recently moved house. This is not an a reasonably cheap single burner
experience I want to repeat anytime that didn’t have a long burner tube to
soon. Part of the process necessarily contend with.
involves discarding the broken and The framework is essentially just
useless stuff. My kwila barbecue trolley four legs with a couple of bars to sit
The finished barbecue
had seen better days, although the basic the barbecue on, two outriggers that
stainless-steel barbecue was worth can be used for the side burner, and a
retaining. I happen to have a reasonable table for placing meat on before and
stock of 40x40mm steel tube and, after cooking. The barbecue is attached
although it is rather heavy, it would do to the base by four screws through the
the job, and at least it won’t rust in a lid hinge.
This meant of course
hurry. If you do emulate this design you I cut all the parts on the bandsaw, cutting the arms
can easily use thinner walled tube — starting with all the bevelled parts. I with bevels on two
even 1.6mm as there is very little weight elected to make the four legs contiguous
in the barbecue itself. with the arms of the outriggers so they
GL̆HUHQWIDFHVZKLFK
are welded together as one piece, rather is fraught with the
Upgrade opportunity than making the outriggers as separate possibility of disaster
I began by careful measurement of pieces and welding them to the tops of
the existing barbecue and designed a the legs.
framework around it. At the same time I prefer using 45-degree angle
I decided to upgrade and purchased joins when possible because they are

Cutting the outrigger piece of the leg Parts cut and ready for assembly

WRJULQGWKH]LQFR̆

Grinding a bevel on the edges

to create a V-groove
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. +%/+)#+%' .)0&, .* - % (, + & + +)&,# . + No need for overkill
% ) +% &% $% + * *'#++) % ))+ .# % . * + + +.& # ,% +* %&. &$'#+
+ $+&-& ,++ %+#*+&%%# ,%)+) *+ &+$&&+) , WDFN ZHOGHG D VWULS RI [PP ÁDW
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Start with the outriggers , +& + #-% 1 &+ % - &+)*&.*#+&,*' &+
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+ * $'&)+%++&++#')'% ,#) +2* #.0* && +& -# +$'&)) #0 . # +" + % '#
% *(,) +& + &,+) ) +# + %* &% ' +& ##&. &) % .%+ " % .# *

Setting up the leg Welding up one of the outrigger tables
Left: Tacking the support for the

outrigger slats
Below: Setting up the crossbars
Grinding off the weld

Test fitting the barbecue
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Adding the lower shelf Thicknessing the timber Planing the edges

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Ripping the slats to size
Having the unit inverted meant that I didnt have to

work on my knees — at my age, that’s something
I prefer to avoid
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Cutting the legs for the castors
Drilling holes for the burner
Tapping the holes
Rounding off the edges
Drilling the screw holes for the lower shelf Fixing the slats

Above: Attaching the hinge
Below: The gas manifold
Marking holes for the barbecue hinge
the piece inverted and the slats in place RI ÀWWLQJV DQG DGDSWRUV EXW DIWHU WKH
I could apply the rivets to get the gaps application of copious amounts of thread
correct and mark where the screw holes tape I have an effective manifold.
were to go. I used two holes for each of
the bottom shelf pieces — it might be
overkill but macrocarpa can curl — and
one each on the outrigger table. Trolley Dimensions
Finishing touches Support for burner

,WKHQKDGWRPDUNWKHKROHVWRÀWWKHOLG Support strips for slats
hinge parts; the screws go through the 260mm
body of the barbecue holding the whole

unit together. I marked the position of 500mm
the holes as carefully as I could then
drilled them to 5mm and tapped them.
Next I set the unit in place and screwed 340mm 832mm 400mm
the hinges through the unit to the base.
Now all that remained was to upgrade
Support for gas bottle
the gas lines. I am fortunate that I have
a branch of Gameco in town and spent
160mm
half an hour with its very helpful staff
sorting out what I needed to make up
a gas manifold to supply both the main 860mm
440mm 540mm
barbecue and the side burner from the
same bottle. I would recommend the
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similar parts. It did require rather a lot

Train shed
The restored 1937 Drewry locomotive

heads out from the workshop

RETIRED TRADIES LEARN
SKILLS — AND MAKE FRIENDS
— RESTORING RAILWAY
CARRIAGES
By Nathalie Brown
Photographs: Derek Golding

Volunteer Kevin Conlan busy at
one of the work benches
E
very Wednesday and Saturday New Zealand Rail when it decamped.
morning about 20 retired tradesmen Several of the volunteer sheddies bring
leave their lunch boxes in the tools from their home workshops; these
Oamaru Steam and Rail Society smoko include magnetic drills, welders, lathes,
room, shrug themselves into their drill presses, and all the woodworking
overalls, and head for the old railway gear needed to make the shapes
workshop to get on with the day’s tasks. and mouldings.
They might be restoring turn-of-the-
20th-century railway carriages, stripping Puke, poo, and diesel
down a locomotive, or installing wiring However, the bulk of the equipment can
systems. Each man brings a lifetime’s be found at the back of the workshop
worth of skills and the willingness to in three old corrugated-iron storage
learn something new. sheds. This is also where a few little blue
They work out of the old New Zealand penguins make their homes. The air is
Rail wagon workshop, or ‘lifting shop’ rich with the smell of engine grease
as it was called, at the back of Oamaru’s and diesel fumes overlaid with penguin
historic precinct. The Oamaru Steam and puke and poo — you’ve got to really love
Rail Society Inc took over the building in the work to spend much time out here.
1989. Most of the tools and equipment But it’s where Harry Andrew, manager
QHHGHG WR FRPSOHWH WKH YROXQWHHUV· ÀUVW RI WKH RXWÀW VWRUHV DQ LPSUHVVLYHO\ WLG\
major project were on hand so they collection of metal pipes and poles, gigantic
rebuilt the 60x12m workshop, which metal structures, tools, and equipment
had been partially demolished by once used by New Zealand Rail. And

This 1921 Fowler is about to be restored
The first carriage restored by the

volunteers was the A1514
The interior view of the smoke box in the

B10 — the Hudswell Clarke locomotive
he knows pretty well what’s here, right

down to the last bucket of bolts and
You’ve got to really love the work to spend
sprockets. The sheds aren’t big enough to much time out here
store everything, so more iron is stored in
old carriages out the back, and down the
sides of the workshop.
Harry sources anything else that Geoff Ellis paints the roof
of one of the carriages
might be needed. He writes the grant
applications for items required for
VSHFLÀF SURMHFWV DQG EHFDXVH HYHU\RQH
in town knows Harry and the impressive
work he does, he is well received when
he visits local engineering shops asking
to borrow specialist equipment such as a
Rotabroach for drilling extra big holes or
thread cutters for bolts and pipes.
Highly skilled team

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tinsmiths, plumbers, a car painter,
a house painter, motor mechanics,

Technical discussions in the smoko room involving, from left, Wally Smaill, Allan Killark,
Geoff Ellis, Phillip Screen and Graham Bull
“We drink a lot of tea

Harry Andrew restored
the DSA 1954 virtually DQGFR̆HHDQGVSHQG
single-handedly over
two years. DJHVWDONLQJDERXW
WHFKQLFDOSUREOHPV´
and general engineers. There are also

retired white-collar workers with
impressive DIY skills.
Harry says, “Most of the men also
come here to learn different things
— things to do with compressed air,
electrical things, mechanical things. A
lot of people haven’t had those linked
and they learn how to link them here.
“If we come up against any problems
around repairs and maintenance, we
discuss it in the smoko room. The
ideas are sketched out on paper and
if necessary we do a bit of internet
research. We drink a lot of tea and coffee
and spend ages talking about technical
problems. From the smallest task to the
big jobs — there’s no rushing in.”
Train WOFs and safety

+DUU\SRLQWVRXWWKDWLQWKHSDVWÀYHRU
six years, the club has focussed on doing
the work rather than just cleaning up
and painting. `

stainless storage solutions
• 430 Grade Anti-Fingerprint
Stainless Steel.
55”
Workstation • Heavy Duty Construction
$1395
72” • Solid Rubberwood Timber Top
Workstation
$1795 • Heavy Duty 150 mm Castor Wheels
• 45kg Drawer Slides
• Soft Drawer Liners
• Aluminium Drawer Handles
• Lockable Drawers
72”
15 Drawer • Stainless Steel Handles
$1295
55” ORDERS AND ENQUIRIES:
10 Drawer mitchell@paceeng.co.nz
$1000
96”
24 Drawer
$1850
95 KATERE ROAD | NEW PLYMOUTH | 06 759 8014 2/355 KAHIKATEA DRIVE | HAMILTON | 07 847 7343
“We decided that,
with enough money to
pay for the parts, we
could do a better job
ourselves”
Community
railway
In the late ’80s, through a fair bit of
wheeling and dealing, the Oamaru
Steam and Rail Society Inc secured
about 2km of dedicated line from
the little station on the edge of the
historic precinct called Harbourside
to the disused quarry at the far side
of the harbour, very close to where
the Oamaru Blue Penguin Colony now
stands. They offer train rides for $20
for a family, $8 for an adult, and $3
for a child every Sunday and, together
with Dunedin Railways, do occasional
excursions to Herbert, 22km south of
Oamaru.
It’s a community railway. There are 110
members in the society and a good
The next job for a team
of men is the fitting of number are families who join for the
new tubes to the B10 discounted rides on offer. There are
some 20 maintenance workers and
about 15 Sunday workers, some of
“We used to farm out the work but to a safety standard that complies with who double up. A trained crew of
now we do as much as we can on our 1=7$ VSHFLÀFDWLRQV 7KHQ DOO WKH WLPH five works on Sundays to operate the
own. We farmed out the steam loco to we have maintenance to do on the locos, little railway: there’s a ticket seller, the
be refurbished and decided that with because they’re old. They break down station master, a guard and assistant
enough money to pay for the parts we and you’ve got to make parts using a guard, a driver — sometimes two
could do a better job ourselves. In fact, lathe, a drill press, all sorts of welders, drivers for diesel — and a fireman if it’s
we save more money by doing it in house and woodworking equipment. a steam train. They work under NZTA
and the men enjoy it more. Recently “Our biggest concern is safety. No rules, and people have to be qualified
we were working on brakes. We’ve shortcuts are taken. We don’t expect to run the trains, even on a 2km track.
modernized one loco that didn’t have anyone to take on big, heavy work alone. Harry Andrew, the manager of
the proper brakes and couldn’t do the job We share it out and work together on it. Oamaru Steam and Rail, can trace
Land Transport [NZ Transport Agency We have a few women involved in the his involvement with the railway in
(NZTA)] wanted it to do, so we’ve station work, and one woman just loved Oamaru back to the centennial in
designed new brakes and put them in. to cleaning our locomotive B10, but 1962 when he rode on the trains as a
“Every year we’ve got to do a warrant here, by choice, the men do the heavy, 15-year-old passenger.
RIÀWQHVVIRUHDFKORFREULQJLQJWKHPXS dirty work.” `

A spanner collage featuring tools collected
by the club over a couple of decades
The B10 nameplate Spare 70-pound (32kg) rails are stacked in the yard

The 1937 TR35 Drewry parked at the
end of the line near the Oamaru Blue
Penguin Colony
Good skills abound ZRRGHQ VODWV EHWZHHQ +H XVHV D

:DOO\ 6PDLOO LV D TXDOLÀHG SOXPEHU EDQGVDZWRFXWWKHHQGVDQGVXSSRUWV “They’re a great
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Some of the volunteer crew (from left): George King, John Lister, Stephen Hinds with Anthea Brown, Allan Killark, Geoff Ellis, Harry Andrew

Three-month project
Harry Andrew steadies the ladder while

Geoff Ellis works on the roof of the CW57,
which is being rebuilt as a service wagon
Murray Jones (left) in his standard running-day
uniform, with Bruce Cawley and Stephen Hinds
Over the Spring of 2017 the volunteers “There’s a lot of welding to be
There is a fair bit of train memrobilia spent much of their time building the done,” says retired motor mechanic
about in the sheds too
Ways and Works wagon — a workshop Kevin Conlan. “We’ve made new
on wheels. It will be used for track doors for it, put in a bench, a new
work, like replacing old wooden metal-plate floor, a vice, and we are
sleepers with modern concrete ones. about to paint it. There are also the
When The Shed visits, the Ingersoll- pipes to carry air the full 20m length
Rand compressor has already been of the wagon. We have yet to install a
bolted to the floor and John Paul (JP) is 12-tonne digger on the front end.
using a lathe to turn out a plug to go “Some of the other jobs we’ve done
in the bottom of a gantry to take the include replacing and painting the
weight when the men lift anything into barge boards on the shed [and]
the wagon. By way of conversation, reconditioning the red loco — the
JP says he served his apprenticeship Husky — so we can take the old blue
as a fitter and turner and has his own loco out of service and do repairs on
machine shop at home. that. And we’ve done quite a bit of
Another two men are linking an air track work, like replacing the wooden
compressor to the reservoir tank sleepers with concrete sleepers, which
underneath the wagon so they can use are a four-man lift. That’s why we want
pneumatic gear. the digger on the front of the wagon.
Restoring the Ways and Works wagon They’re a great bunch of fellas and this
is a three-month project, two days a really gives us something to keep us
week, for about five men. occupied two days a week.”

The track and yards lie behind
Oamaru’s historic precinct
The brake gauges in the

steam engine B10
This 1901 postal car now serves Harry is understandably

as a timber-working workshop proud of his DSA 1954

Trading
equipment
The railway equipment and spare
parts stored in the three sheds and
railway carriages behind the Oamaru
Steam and Rail workshop are not
always sufficient to do a particular
job. “We trade the equipment
we’ve got in storage with different
railway groups,” says Harry Andrew.
“We belong to the Federation of
Rail Organisations of New Zealand
(FRONZ), which has about 90 railway
groups, and we can advertise in their
magazine to buy, sell, or exchange
most of the gear we need. The
federation tries to keep all its costs
down, so the magazine is only in an
online format but as soon as they
send it to me I forward it on to all the
Oamaru Steam and Rail members.”
www.fronz.org.nz/journals

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Two diesel and one steam-driven

locomotives line up in the workshop.
From left: Kevin Conlan, Murray Jones

(obscured), and Geoff Ellis press a bearing
into a housing
Plenty to do and learn has been restored but they have yet to
` Some of the men are working on bring in the grant money to restore the
installing public-address-system wiring 40 leather seats. The guard’s van has
throughout the newly restored train also been rebuilt and to a certain extent
carriages. The work is supervised by reappointed. Volunteers built a heavy
Phillip Screed, a volunteer and retired aluminium loading ramp to take the
electrician. wheelchairs of disabled passengers, who
The club members have restored ride in the restored 1947 guard’s van,
two carriages: a 1904 and a 1924. The which also houses the new PA system.
1904 glories in 70 wooden-slat seats, Ask any of the sheddies at the steam
wrought-iron seat ends, wood-panelled and rail workshop and they’ll tell you
walls, a pressed-tin ceiling, and replica that there’s always some new project to
OLJKW ÀWWLQJV 7KH KDV DOVR EHHQ be worked on. There’s always something
rebuilt by the team of volunteers. When more to learn, and good friendships are
Harry found it, the carriage had been being made and cemented among men
used as a welder’s workshop. Much of it who share a common interest.

Pottery making
T he
Magic Mud of
A POTTER’S FIRST RULE WHEN MAKING HER

QUIRKY PIECES IS THAT THEY MUST BE A DELIGHT
TO USE EVERY DAY
By Sue Allison
Photographs: Juliet Nicholas
Weighing clay after kneading to ensure

bowls are all of uniform weight/size for
easy stacking and good appearance

Renate kneading clay to expel air Various finished items ready for sale
C
hristchurch potter Renate Galetzka gallery in return for lessons. Renate EHIRUH EHLQJ ÀQLVKHG ZLWK D FOHDU RYHU
draws inspiration for her colourful went on to run and teach pottery at the JOD]HÀUHGWR&
and quirky pots from her daughter’s Risingholme Community Centre. Renate works from home in a converted
stint as a circus trapeze artist and the two-car garage in the seaside suburb of
books of Dr Seuss. Traditional engobe Brighton. Her equipment includes two
“I want to make people smile,” says earthenware electric wheels — a Japanese Shimpo
Renate, whose pots are fanciful but In the early 2000s, she and Liam spent for dark clays and a New Zealand–
functional, made to be used not left on several years in Switzerland where Renate made Cowley for her more often-used
the shelf. “I make pots to brighten your did an adult apprenticeship in ceramics white ones. She has a bench grinder
day every day.” at the Schule für Gestaltung (School of for sharpening tools, a skill saw, drills,
German-born Renate met her Kiwi Design) in Zurich. Here, she became and an array of buckets and sacks full of
husband, Liam, in the Abel Tasman interested in the traditional ‘engobe’ clays and glazes. But otherwise her shed
National Park in the 1980s. “I was on an earthenware of the Swiss mountains, VHHPVWREHÀOOHGZLWKLWHPVPRUHRIWHQ
OE and I’m still on an OE,” she declares, which uses coloured clay slurry, or ‘slip’, found in the kitchen: an electric frying
and part of that on-going overseas as a decorative underglaze. Renate pan (for waxing), a rolling pin, pastry
experience included discovering has adapted the technique to her own sticks, spatulas, potato peelers, even a
the art of ceramics. She took hobby designs, painting and trailing stained three-tier tea trolley — “In our house, if
classes in Christchurch, followed by slips to produce colourful raised patterns \RXFDQ·WÀQGVRPHWKLQJLQWKHNLWFKHQ
“work experience” with one of the on her pots. The decorations are applied look in the garage,” says Renate.
grand dames of New Zealand pottery, to the raw, dry clay, after which the pots But her favourite modelling tool — and
Frederika Ernsten, looking after her DUH ÀUHG WR ORZ ¶ELVFXLW· WHPSHUDWXUHV there is some pleasure in seeing it covered

Tectonic pot
Every year Renate embarks on an coats the outside with a chemical that coloured ceramic stain. “Sometimes
experimental project. Last year’s was prevents the clay from stretching. it works and sometimes it doesn’t. If
tectonic bowls. To create the colourful “From then on, you can only work from you aren’t careful, it just rips open.”
cracked surface, Renate first pulls the inside, pushing the clay out a bit at Renate coats the outside with wax
up a cylindrical shape then covers it a time.” The pressure creates cracks on to preserve the effect before glazing
with black slip. Once this is dry, she the outside surface, which she fills with inside the pot.
in mud — is a credit card. Although 5HQDWH WDNHV UHWULHYHUGRRGOH 0LOO\ IRU

Coloured paints/dyes and brushes
purpose-made tools can be purchased DZDONEHIRUHWKH\VHWWOHLQWRWKHVWXGLR
online, nothing beats a credit card for the IRU DURXQG VL[ KRXUV HDFK GD\ WXQHG
ÀUPEHQGLQHVVUHTXLUHGZKHQVKDSLQJD into National Radio.
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“I was on an OE and
Preparing the leather-hard surface I’m still on an OE”
before attaching the handle
Nice to use a bit sparkly”. Renate supplies a number The process

Renate uses Mac’s Mud man-made white of galleries around the country, as well as Wedging: Clay must be ‘wedged’,
clay for most of her work. Her pots are working to exhibitions and private orders. or kneaded, before use to remove any
microwave- and dishwasher-proof and air bubbles and get a homogenous
she only uses food-safe glazes. A stickler consistency. When making a set of
for producing well-made domestic ware, uniform-sized pieces, Renate weighs the
she emphasizes the importance of light, clay on a set of vintage scales picked up
well-thrown pieces. in an op shop for $5.50. She uses 600g
“Sometimes you buy things because for her muesli bowls. “If you want bowls
you like the look of them but they end to stack, you have to be precise,” she
up at the back of the cupboard because says. The clay is wedged with a rhythmic
they aren’t nice to use.” roll-press-roll-press motion. While it
Proof is in the pudding, and her resembles kneading dough, it achieves
domestic ware is sought-after by the opposite — expelling air rather than
restaurants, with a recent order for a lightening a loaf.
new Christchurch eatery incorporating Throwing: The process of making
earthquake liquefaction in the glazes. “I a pot on a potter’s wheel is called
collected liquefaction from three different ‘throwing’, strangely.
sites around the city. I knew I wanted to “You throw the lump of clay into
use it in something sometime.” She added the centre of the wheel to start with,
the strained silt to the glaze, making it “go One of Renata’s unique ‘tools’ but that’s the last time a pot should be

Several aspects of throwing/
turning a bowl using various
reused ‘tools’ in the process,
including credit cards, baking
utensils, etc. Note the well-
positioned mirror that enables
her to see her creation side-on
while she is wheel turning
Renate starts by decorating the

foot of the bowl.
Forming and attaching a handle to a mug

The application of decorative colours
by brush. After this, the raised slip is
squeezed on from a plastic bottle

thrown anywhere,” says Renate. It turns leather hard. The handles are attached
out the term comes from the Old English with slurry mixed with a little vinegar
‘thrawan’, meaning to twist or turn. to help them adhere. She scratches the
Renate forms a dome with wet, cupped points of attachment with an expired
hands, then presses her thumb gently but OLEUDU\FDUGFXWZLWKÀQHWHHWKTXLFNHU
ÀUPO\GRZQZDUGVWRIRUPDQRSHQLQJDW than scratching with a sharp tool). She
the centre. She takes care to compress paints slip on the attachment points,
the base to prevent it cracking when it leaves it to dry until tacky, then gently
dries. The thickness of the base can be presses the handle into place.
measured with a needle. Renate works Decorating: Renate buys powdered
quickly, regularly wetting the clay with pigments to make her own slips, mixing
a sponge as she brings the form up. about 50g of pigment with 200g of slurry.
A mirror propped on the wheel ledge 7KHVWDLQVÀUHWR&ZLWKRXWORVLQJ
allows her to see the shape side-on. colour. She uses a hand-spun banding
Renate uses her trusty credit card to take wheel marked with concentric circles
off any surface slurry and to compress for decorating, resting the bone-dry
the sides. Once the sides are stable, she bowl on its rim while she decorates the
opens the form, using a pastry scraper to base area. Renate buys cheap brushes
shape the inside of the bowl. but ones that carry a “good load” to
Fishing nylon on a champagne cork hand-paint her decorations and uses slip
is ideal for cutting off the pot, which trailers to draw black spirals, outlines,
she then puts in a sealed polystyrene and dots. She adds a few drops of bleach
box to dry at an even temperature.
An allowance of 12- to 15-per-cent
VKULQNDJH GXULQJ ÀULQJ QHHGV WR EH
States of clay
made, depending on the clay.
Renate’s kiln is partially powered Turning: After a couple of days,
by solar panels on her roof the bowl will be leather hard and ready
to have its base and foot ring ‘turned’.
5HQDWH WXUQV WKH SRW RQ D ÁDW FHUDPLF
It seems that this mild- ÁRRUWLOHDWWDFKHGWRWKHZKHHOZLWKZHW
clay. She draws concentric circles on it
mannered potter, who
with a pencil so that the centre is easy
also crochets and knits WRÀQG6KHVWLFNVWKHERZOULPGRZQ
her own socks, is a to the centre of the tile with water —
third-degree black belt “Some people secure it with blobs of
FOD\EXW,ÀQGLWGLVWRUWVWKHULPµ
After giving the surface a quick tidy- ‘Clay’ is finely-grained earthy material
up, she starts shaving off ribbons of clay composed mainly of hydrated silicates
around the base with a steel turning of aluminium. Clays are plastic due to
tool. (The discarded clay is re-wedged their water content and become hard
or used to make slip.) The bowl’s shape when fired in a kiln.
should continue through the foot ring. ‘Leather-hard’ clay has been partially
5HQDWH WDNHV RII DQ\ ÀQJHU OLQHV ZLWK dried, with about 15 per cent of its
a kidney-shaped tool to leave a smooth moisture content remaining, leaving
surface for decorating. She inverts it to it firm but not brittle. It can be cut
tidy the rim, then places it upside down without distorting the form.
to fully dry. ‘Bone dry’ refers to clay that has no
Making handles: To make her moisture content and is ready to be
distinctive tail-like cup handles, Renate fired. It is brittle at this stage.
rolls coils, keeping them fatter at the ‘Fired’ clay has been chemically
top. She cuts each to length and slaps it transformed, irreversibly, whether into
RQWKHEHQFKWRÁDWWHQRQHVLGH´,I\RX the lower-temperature ‘bisque’ state or
have a handle that’s completely round, high-temperature vitrification, which
LW·VGLIÀFXOWWRKROGµVKHVD\V6KHFXUOV also fuses the glaze.
them to shape and leaves them till

Proof is in the
pudding, and her
domestic ware is
sought-after by
restaurants
to the black stain to stop it going mouldy

and clogging her slip trailers. The slip
has the consistency of thick cream and
the moisture is quickly absorbed by the
dry, porous clay. She holds the bowl in
one hand to decorate the upper part and
LQVLGHÀQLVKLQJZLWKWKHULP7KHERZO
LVWKHQELVFXLWÀUHGWRDURXQG&
Waxing: The base or foot ring of a pot
must be waxed before glazing or the
glaze would stick to the kiln shelves.
5HQDWH ÀQGV DQ HOHFWULF IU\LQJ SDQ WKH
best device for waxing as she can roll the
base evenly in the heated wax without
having to paint it on by hand.
Glazing: Renate buys glazes by the
sackful, mixing them with water and
storing them in buckets. The heavy
glaze materials sink to the bottom, and
VKH ÀQGV WRLOHW EUXVKHV WKH EHVW WKLQJ A fun and quirky clock
for stirring her glaze buckets. Tongs
are used to dunk the pots in the glaze.
The clear glaze used over slip-decorated
SRWVLVRSDTXHXQWLOÀUHG Candlesticks
Firing: Renate uses high-temperature
HDUWKHQZDUH FOD\ ÀUHG LQ DQ HOHFWULF
NLOQWR&,WWDNHV²KRXUVWR
get the temperature up, a pyrometer
UHDGLQJWKHWHPSHUDWXUHWRZLWKLQ&
Once the kiln has reached the desired
WHPSHUDWXUHVKHWXUQVLWRII,WLVVRZHOO
insulated that the temperature comes
down very slowly. Once the kiln is down
WRDERXW&VKHSURSVRSHQWKHOLG
,W·V LPSRUWDQW WR UHVLVW WKH WHPSWDWLRQ
to lift the lid too soon or the pots will
FUDFN´,W·VDVKRFNQRWRQO\WRWKHSRWV
but also to the electric elements, which
are expensive,” says Renate. Renate
UHFRUGVHYHU\ÀULQJLQDQH[HUFLVHJUDSK
book, from the contents of the kiln to Renate’s candlesticks are made by
DQ\ SUREOHPV ´6RPHWLPHV , KDYH D throwing the individual beads on the
disaster,” she says. One notable one was wheel and drilling a hole in them when
GRFXPHQWHG RQ )HEUXDU\ WKH they are leather hard. She stacks them
GD\RIWKHELJ&KULVWFKXUFKTXDNHZKHQ on a steel rod on a polished stainless-
with a mere mess of pots stuck to the steel base, which she gets made by a
kiln shelves, the philosophical potter local metalworker.
Colourful Salt Pig
simply counted her blessings.

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Electronics
Desolder pumps, with Phillips one on the

left — note its smaller length
T
he other day I was having a
conversation with The Shed editor
Greg Vincent, and I realized that
although we have been doing a variety
of articles on electronics, we haven’t
talked about the tools needed to do
decent work.
Everyone knows that at some stage you
need to blame your tools (after the other
excuses have run out), and like most
things you can pay a little money or a lot,
and sometimes there is little difference
in the result … or so it would seem.
The purpose of this article is not to
separate you from your hard-earned
cash, but to share a few tricks and provide
some information so you can make an
informed choice when buying equipment.
Stations and irons

Everyone knows that the best soldering
iron is some large lump of material that
\RXWKURZLQWRWKHÀUHXQWLOLWLVUHGKRW
and then apply to the job and hope that
some of the exploding material fuses the
bits together.
That might work for simply joining
two bits of metal together but it is not
going to work for electronics.
Soldering electronics involves making
not only mechanical bonds but also
electrically conductive joints. The solder
used has a particular temperature range
and if it is too hot it will overheat the
joint and make it porous, while if it is too
cold it may stick to one or another part
but not bond.
The basic soldering iron consists of a
heater and a tip. The wattage is limited
to 25–40W to stop overheating the tip. It
works well on small joints and relies on
the thermal mass for larger joints.
PA R T O N E As it takes time to warm up, it tends to
get left on and there have been attempts
to reduce the heating with inbuilt or
ALL SOLDERING EQUIPMENT IS NOT CREATED aftermarket controllers, much like a light
dimmer, which simply reduce the power
EQUAL. HERE ARE SOME TIPS AND TRICKS applied and therefore the maximum heat.
Clever versions detect when the
By Mark Beckett iron is in the stand and put full power
back on when it lifted, but the thermal
Photographs: Mark Beckett
lag becomes a nuisance and often is
bypassed.

Correct iron and solder placement (photo is
without heat to show placement)
A solder joint where the solder

has not adhered to the connector,
resulting in issues later
I have never really

paid any attention
when I’m soldering —
it’s either hot enough
or not
Temperature-controlled
irons
Weller produced a version that controlled
the temperature by using a magnet
inside the tip. As the tip heated to the
desired temperature, the magnetic force
reduced and switched off the heater. As
the tip cooled, it switched back on. The
tips were expensive but lasted for many
years if looked after.
Since then electronics has taken over
and there are a range of stations with
adjustable temperature control, either
by using a setting or a knob.
Some models include active measuring
of the tip temperature, although I have
never really paid any attention when I’m Desolder pump placement while
heating the solder joint
soldering — it’s either hot enough or not. `

Using gravity to assist with
the removal of excess solder
The temperature control approach has IURPKRUL]RQWDOWRYHUWLFDORQERWKVLGHV DEOH WR VHH LW PHOW DQG GLVSHUVH $W WKLV
allowed a much higher wattage iron to ZHOOLWGRHVLQWKHSLFWXUHV SRLQWUHPRYHWKHVROGHUthenWKHLURQ
handle the wide range of solder joints we 7KH ERDUG 3&% SDG DQG FRPSRQHQW $GDIUXLW KDV D YHU\ JRRG JXLGH WR
ÀQGRQPRGHUQFLUFXLWERDUGV wire are heated equally and then solder is VROGHULQJ DQG SUREOHPV KWWSVOHDUQ
As a consequence, the time to warm up DSSOLHGWRFRPSOHWHWKHMRLQW7KLVZKROH DGDIUXLWFRPDGDIUXLWJXLGHH[FHOOHQW
KDVEHHQUHGXFHGDORQJZLWKWKHWKHUPDO SURFHVVWDNHVOHVVWKDQÀYHVHFRQGV VROGHULQJ
PDVVSUREOHPZLWKODUJHUMRLQWV $SSO\LQJKHDWWRDSULQWHGFLUFXLWERDUG 6ROGHULQJ WDNHV SUDFWLFH DQG VRPH
Rework stations often include a 3&% SDG IRU PXFK ORQJHU LV OLNHO\ WR SHRSOH QHYHU VHHP WR EH DEOH WR PDVWHU
VROGHULQJLURQEXWLI,ZHUHWRSXUFKDVH OLIW WKH SDG IURP WKH ERDUG JLYLQJ \RX LWVRGRQ·WZRUU\LI\RXVWUXJJOH«\RX·UH
RQH VHSDUDWHO\ ,·G EH ORRNLQJ YHU\ KDUG DQRWKHULVVXHVRXQOHVVLWLVDYHU\ODUJH QRWDORQH
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at 98 0 d- eu /s olde r i ng- s t at ion- 8 0 w- Poor solder joint
YDFHXGS"USVNX FORQH The state of flux 6R QRZ ZH KDYH D JRRG VROGHULQJ LURQ
LVH[FVNX WUXH 2QH SUREOHP ZH VHH LV WKDW WKH LURQ LV and we use the right technique, what can
placed on the joint and solder is applied JRZURQJ"
Proper solder joint onto the upper surface of the tip, )RU SURSHU ERQGLQJ WR RFFXU ERWK
:KHQ LQWURGXFLQJ WKH VXEMHFW RI rather than at the junction of the pad VXUIDFHV QHHG WR EH FOHDQ DQG VKLQ\ ,I
electronics, pupils are taught how DQG FRPSRQHQW 6ROGHU IRU HOHFWURQLFV WKHFRPSRQHQWV\RXDUHXVLQJKDYHEHHQ
to solder and how to recognize the FRQWDLQV D UHVLQ ÁX[ DQG WKH ÁX[ JHWV sitting around, then the tin coating may
GLIIHUHQFH EHWZHHQ D JRRG VROGHU MRLQW EXUQWRIIZKHQLQFRUUHFWO\DSSOLHG KDYHR[LGL]HGZKLFKFDQFDXVHSUREOHPV
DQGRQHWKDWPD\FDXVHSUREOHPVODWHU 7KH VPRNH DQG YLVLEOH IXPHV DUH <RXFDQ¶WLQ·WKHFRPSRQHQWOHDGEHIRUH
7KHVKDSHRI0RXQW)XMLLVDQH[DPSOH indicators of this happening, along inserting it, or sometimes the soldering
of what a good solder joint should look ZLWK GDUN ÁX[ UHVLGXH RQ WKH ERDUG %\ SURFHVVÁX[ZLOOFOHDQLW
OLNH:KHQYLHZHGLQSURÀOHWKHPRXQWDLQ applying solder down at the intersection ¶7LQQLQJ· LV ZKHQ \RX DSSO\ KHDW
KDV D FXUYH RU ¶ÀOOHW· LQ WKH WUDQVLWLRQ RI WKH ERDUG DQG FRPSRQHQW \RX·OO EH and solder to the component only and

Here the solder has not adhered to the There is too much solder, which could be
component lead either due to oxidation or masking a poor connection to the PCB pad
use of the wrong technique
the result is a light coating of solder. It has its place and cost for the tools more frustration and damage than they
may release the impurities (often dark- required. are worth.
looking reside), so sometimes a quick Here, we will talk about cheap, simple The technique is to apply the soldering
wipe is required to be sure it doesn’t get tools, and in a later article touch on iron onto the wick and then onto the
into the solder joint. desoldering stations. solder joint. The heat goes through and
If the board is not shiny, then a pencil it pulls the solder away from the board.
eraser works wonders to remove any Desolder braid/wick The heat and force can lift solder traces
oxidation. I’ve heard people swear by desolder so be careful about how long it is used in
braid/wicks and I’ve heard people just one spot. It is very useful for cleaning up
Solder solutions swear. holes, but then so is a solder pump.
You may have applied too much solder ‘Solder wick’ is a copper braid-like Don’t be fooled — they come in
and the joint is covered, so you can’t be product that soaks up the solder. It is different widths and the cheap stuff may
sure if it has bonded. more suited to SMT but is useful to not work as well. This soldering guide
0\ÀUVWVROXWLRQWRWKLVLVWRXVHJUDYLW\ remove excess solder. is rather good, and they use the braid/
to remove the excess solder. I turn the It comes in different sizes and there wick to clean up a joint: https://www.
board upside down and apply heat to are some cheap products that cause sparkfun.com/tutorials/96.
the solder joint, then pull it down the The through-hole soldering guide
component lead and away from the joint. is here: https://learn.sparkfun.com/
The next solution is to desolder it. tutorials/how-to-solder---through-hole-
7KHJXLGHVDOZD\VWDONDERXWÀQLVKHG soldering. `
solder joints being nice and shiny, and Solder wick — 2.6mm
while that is true for lead-based solder, width in a handy dispenser
the move by manufacturers to lead-free
solder results in a dull surface.
Soldering takes
Surface-mount-technology (SMT)
solder joints are far less obvious and the practice and some
method, tools, and solder used to join the people never seem to
component to the board is different.
be able to master it, so
Desoldering don’t worry
This is the process of removing solder, if you struggle …
usually with the aim of separating the you’re not alone
component from the PCB.
There are several methods and each

Relative sizes of desolder pumps
against AA batteries
Desolder pump two joints, but can be a pain to use. To

A ‘desolder pump’ is a tube with a use them, you press down the plunger
spring inside that is released, causing to compress the spring. Heat up the joint
I should have
a vacuum at the tip. The soldering iron and bring the nozzle as close as you can,
and desolder pump are applied to the then press the release button. bought three or four
joint and once the solder is melted, the As the plunger is released it sucks at the time, because
spring is released and the solder gets up the hot solder inside the pump. they don’t seem to be
sucked up the tube. Obviously, the closer the nozzle is to the
available anymore,
It is a bit of an art but with some luck joint, the more effective it is.
mixed with dexterity, you can easily suck The best model I have is a Phillips- so I’m looking
all the solder from the joint. Again, excess branded version that is slightly smaller after mine
heating of the pad can cause it to lift. than others and utilizes a smaller
Desolder pumps work well on one or QR]]OH 7KLV PHDQV \RX·UH QRW ÀJKWLQJ

A metal plunger rod
extends past the end to
clean out solder from
the nozzle
The internal components of a twist-lock-style

desolder pump
the soldering iron for the same space and are meant to be used with one hand. suction more quickly; however some argue
the suction velocity is higher. Element14 has a good range, with varying that Mr Newton’s third law of equal and
I should have brought three or four at the types and different prices; you can expect opposite force means it makes contact with
time, because they don’t seem to be available to pay from $5 to $70. the heated pad and increases the damage.
anymore, so I’m looking after mine. My suggestion is to buy one that screws Whatever version of solder pump you
WRJHWKHUDV,·YHVHHQWKHRWKHUVÁ\DSDUW buy, make sure you grab a couple of
Buy and try I usually stretch the spring to apply extra tips for it.
Something to watch for are desolder
pumps models that have the nozzle
inserted from the outside.
When you push the plunger down fully,
it protrudes through the nozzle to clean
out any solder lodged on the sides. With
the external-insertion-type nozzle, they
can be pushed out.
Models with softish nozzles can deform
rather than clean out properly.
The only maintenance is to make sure
the O-ring is clean and lubricated, and
check that the nozzle is not damaged.
Along with replacement tips, they should
outlast your ability to keep soldering.
It’s rather hard to see all these things
just from looking at a catalogue, so don’t
be afraid to ask at your local suppliers or
EX\GLIIHUHQWW\SHVXQWLO\RXÀQGWKHRQH
you want.
In the next issue of The Shed, we'll talk about desoldering
If you have smaller hands, the length stations like this one
can also be very important as they

3D printing
PA R T T H R E E
THE THIRD PART IN OUR 3D PRINTING
SERIES LOOKS AT THE IMPORTANCE OF
SETTINGS IN ACHIEVING AESTHETICALLY
PLEASING RESULTS
By Enrico Miglino
Photographs: Enrico Miglino
I
n this third part of our series, we will renderings in the illustrations on these
address the 3D printer setting details SDJHV 7KH SURFHVV GHVFULEHG FDQ EH
by following a real-world creation: the easily applied to plenty of 3D-printed
model mock-up of the PONF camera (the VWDWLFPRGHOV
RIÀFLDO VLWH LV KWWSSRQIFDPHUDFRP
an innovative project aimed at creating Bed calibration
WKHÀUVWGXDOEDFNGLJLWDODQGDQDORJXH We mentioned in a previous article
UHÁH[FDPHUD the importance of the correct bed
This is a kind of 3D-printed item FDOLEUDWLRQ IRU D JRRG SULQWLQJ MRE 7R
for which the aesthetic result is a key proceed to calibrate the 3D printer
IDFWRU 2XU JRDO LV DFKLHYLQJ DV PXFK bed manually, we will adjust the
DV SRVVLEOH WKH VDPH VNHOHWRQ that the four calibration screws, one at every
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here is not limited to the bare 3D printing easier, some models provide only three
RI WKH 67/ ÀOHV EXW DOVR LQYROYHV VRPH FDOLEUDWLRQSRLQWV,KDGWKHRSSRUWXQLW\
LQWHUHVWLQJFUDIWZRUNSRVWSURGXFWLRQ WR XVH ERWK PHWKRGV DQG IRXQG WKDW ,
7KHÀUVWVWHSZDVFUHDWLQJWKHGHVLJQ obtained better results with the four-
of the components with Rhino 5 CAD VFUHZV\VWHP7KHSURFHGXUHLVQRWWRR
software — you can see some of the 3D GLIÀFXOWEXWVKRXOGEHSUHFLVH`

Above and below: The transparent rendering
of the camera assembled with the digital back.
Note how rendering shows also the electronic
components at real size in place as they will
fit in the real object. This modelling is the
last step before starting to make a physical
prototype for testing
Four-point calibration RQ HYHU\ FRUQHU LV QRW VXIÀFLHQW ³

procedure modifying the distance of one corner of
Position the extruder making the Z-zero The process we the bed slant will affect the settings of
at about .5mm from the bed. The 3D the other three corners. So you will need
describe can be easily to repeat the four-corner calibration
printing software has an auto-zero
function to position the extruder nozzle applied to plenty of 3D until the distance value is constant
at the axis origins. printed static models at all the test points. It is important
Using the manual controls on the to note that the calibration process is
printer or the 3D printing software, QRW D VWDEOH FRQGLWLRQ ³ WHPSHUDWXUH
PRYH WKH H[WUXGHU QR]]OH WR WKH ÀUVW screw to the right distance. Repeat the variations during print jobs and other
corner. No matter what method you same procedure on all the four corners. factors affect the settings. It is good
choose, check the distance of the nozzle The optimal distance between the practice to check the bed calibration
from the bed surface with a .10mm thick QR]]OH DQG WKH ÁDW EHG VKRXOG EH frequently and always before starting a
feeler and rotate the corner calibration .5–.7mm. However, one calibration new job.

The 3D components ready for 3D printing.
These are the same files included in the
GitHub repository
Automatic calibration Unfortunately, the auto-levelling ìnstructions, compensating for the bed
Alternatively, the manual procedure sensor cannot be considered 100-per- misalignment. This is as if the extruder
can be automated with a 3D printer cent trustworthy. It can detect the bed were correctly moving over a non-plane
auto-levelling sensor. This is a tool slant but will not change its orientation. surface. It risks introducing a systemic
permanently applied to the extruder, During the 3D printing process, error, resulting in imprecise object
which is able to detect the distance from WKH FRQWUROOHU ÀUPZDUH DSSOLHV WKH generation.
the bed. The automated process has pros mathematical corrections to the G-code During the past couple of years, this
and cons and can be applied only with
compatible 3D printers.
Pros: The automatic levelling sensor
is a good choice if the user has no
experience and is not sure of being able
to carry out the manual calibration.
The automatic levelling process is faster
DQG FDQ EH YHU\ HIÀFLHQW LI WKH EHG LV
(almost) aligned correctly. After the
sensor installation, it is easy to use.
Cons: The sensor is not expensive but
not super cheap, either. If it is included
with the 3D printer it can increase the cost
of the device as a meaningful value-added.
The extruder model and 3D printer should
be compatible with the sensor installation.
The 3D printer controller board should be
compatible; an extra connector for the
level sensor should be available on the The toolset used to finish the 3D-printed components before painting. The surfaces were
completed with multiple passes with sandpaper (800 and 1200). As electric tools heat
ERDUG $ ÀUPZDUH XSJUDGH LV QHHGHG WR up and PLA plastic material tends to melt when it becomes hot, the process can only be
make the sensor work correctly. completed by hand

This page and top of next: The bare tool has become more popular and
3D-printed parts of the model. Now the
finishing process should be applied, before there are always more 3D printer
the parts get painted models arriving that are compatible
with or include the sensor in their
original build specs.
STL model control

parameters
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can achieve very different results
and qualities depending on how
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Our choices depend on what kind of
object we are creating and its usage.
In our case, we are building a model,
so aesthetics is more important than
robustness.
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layer-thickness settings.
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speed within an acceptable range,
as the faster the extruder moves the
greater the loss of precision. Consider
WKDW HYHU\ ÀODPHQW KDV LWV RZQ EHVW
3D printing speed. Different materials
have different fusion temperatures and

The camera body’s two-parts. The interior will host the re ex mirror and has been left rough without paint, to enforce the material difference
with the exterior, finished and painted. The chassis parts of the camera will be produced with light Aluminium or Magnesium while the internal
components will be a plastic molded shell to host electronics and flat connectors.
different physical characteristics. For 180°C) is easier to manage. I prefer to

example, ABS (acrylonitrile butadiene XVH3/$DV,JHWPRUHSUHFLVHUHVXOWV
To achieve good styrene) LV PRUH ÁH[LEOH WKDQ 3/$ :KHQ ZRUNLQJ ZLWK GLIIHUHQW
(polylactic acid), has a higher fusion materials, you should consider adopting
quality with a DIY 3D temperature (about 220°C) and the GLIIHUHQW FRQÀJXUDWLRQ VHWWLQJV LH
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Finishing the surface makes it ready for

painting and easy to insert the mobile
components

Metalized and black
painting of the finished
parts done with matte
black and aluminium
metalized spray paint.
To obtain a good
surface effect, every
piece was painted five
times very lightly to
avoid imperfections as
much as possible
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3D Printers Flashforge
CREATOR PRO
DREAMER
• 227x148x150mm
• 230x150x140mm
• Steel Chassis
• Dual Head
• Dual Head
• PLA and ABS Printing
• PLA and ABS
Printing
FINDER
• 140x140x140mm
• Safe and Quiet
• Prints with PLA
ORDER ONLINE AT
Fill percentage
As there will be no The CuraEngine supports a
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mechanical stress on :LWKDSHUFHQWÀOOVHWWLQJZHPDNH
these components, D VROLG SODVWLF REMHFW ,Q P\ H[SHULHQFH
printing at full density ZLWK PDQ\ SULQWLQJ H[SHULPHQWV D
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The finished model of the camera body (above) with the Aluminium M43 ring for the lenses
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and the finished analog back model (below).
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1. Preparing the components

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The finished model with a lens mounted on it. This should be the camera skeleton structure.
The industrial designer’s crew will start from this model to “dress” the object with the final plastic
components like the hand grip, external texture, protection parts and connector closures

UHPRYLQJWKHVXSSRUW,VXJJHVWXVLQJDÀOO UHSDLQW , DSSOLHG ÀYH OD\HUV RI SDLQW WR Note that the digital back has a
rectangular area to fit the LCD
GHQVLW\QRWORZHUWKDQSHUFHQW DFKLHYH WKH EHVW UHVXOW ,I \RX ÀQG VPDOO screen. To print this part of the
GURSV RQ WKH VXUIDFH EH SDWLHQW :DLW model it was necessary to set up
the support while printing
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SUDFWLFHWRXVHHOHFWULFWRROVOLNHD'UHPHO For the software download of this series
EHFDXVH ZKHQ URWDWLQJ UHODWLYHO\ VORZO\ of articles, head to https://github.com/
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The three-part finished model

with a lens mounted on it

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Outdoor fires

USE THESE TECHNIQUES AND TIPS
TO GET PROFESSIONAL-LOOKING
FINISH ON YOUR OUTDOOR
FIREPLACE
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Grind high points

off the mould,
then put a fine
100mm fibreglass
mesh over the
joins
Once this is
applied, apply
a flick coat (or
scratch coat)
Use the flick-coat

method only for a
sand and cement
system
I
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Plastering
tips and tricks
• The structure needs to be dampened
down with a hose prior to plastering.
• This kitset is pumice based, so it will
suck the plaster onto it. Applying a
masonry sealer first will make it easier
for a handyman to stop the sucking of
moisture and reduce work time.
• The plaster needs to be 25mm thick.
To ensure consistency, the straight
edge can come in handy to make up
for any variation in moulds.
• The sand and cement system needs
to be hosed with plenty of water the
day after application to reduce or
eliminate cracking.
• Fine-mesh coat requires resin.
Always check your

VWUXFWXUHLVOHYHO¿UVW
This is the sand cement used for the key coat only
— it may have sunk
into the dirt as it has
settled
Key-coat mix
Plaster perfection to use because of its formula that uses

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decided to go for a sand and cement RSSRVHGWRFRQFUHWHZKLFKFDQEHTXLWH
SODVWHUÀQLVKRQWKHLUÀUHSODFHVRKHUH tricky.
we’ll step you through what’s involved Always check your structure is level
and give you a few expert tips and tricks ÀUVW ³ LW PD\ KDYH VXQN LQWR WKH GLUW
for the plastering process. as it has settled over the time since
,I \RX·YH GHFLGHG D SODVWHU ÀQLVK LV installation. Our one was 25mm
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to consider. One is a bagged product that this difference with the plaster. The six-inch broad knife used for
We used a steel trowel to apply our mesh-coat application and the
KDVDÀEUHFDOOHG¶3XW]·LQLWVPL[7KLV
trowel used for sand and cement
makes it easier for the non-professional plaster. ` application

Left: Yellow
plastic trowel for
more accurate
finishing
Right: Blue trowel
used for a more
rustic finish
Below left:
Textured finishes
can hide a
multitude of sins
Above and below: The flick coat can be applied with a cut down
block layer’s trowel
The scratch coat on perimeter around stainless

and refractory components

Above: Key coat ready for sand and cement
Below: Plaster needs to be applied to the

corners to hold and form straight edges. For
this to be achieved, a smooth piece of timber
or aluminium should be used
Once applied and levelled we can then trowel

on the mortar, being careful not to move the
straight edge. It can help to have someone
holding the straight edge. Now that the edge
has been formed, you’ll need to screed off
excess plaster by shaving small amounts on a
45-degree angle upwards from the inside out to
prevent the corners collapsing. It is preferable to
use a slightly bowed piece of sharp-edge timber
for this step (we used a 40x10mm piece of sharp-
edged pine timber from Mitre 10)
Done and dusted

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friends will no doubt
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process in excruciating
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light it up. hand. Nice.

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Enjoy!
Steampunk toys
THE FUN OF MAKING STEAMPUNK TOYS REQUIRES

EQUAL AMOUNTS OF CREATIVITY
AND RESOURCEFULNESS
By Coen Smit
Photographs: Coen Smit
A
steampunk toy (for want of a better exhaust was rescued from a kitchen tap when possible, the three-wheeler can
term) combines two passions of shroud and the radiator had a past life as also do duty as a light for a side table
mine. First, I love making things a heat sink in a computer. or cabinet.
that are a bit different, even a bit quirky. My inspiration for these toys generally
Something that stands out from the starts with a central component or two,
run of the mill stuff that you buy at the I love making around which the rest of the toy is
shops. Second, I enjoy the challenge of fashioned. Once I have decided on these
things that are a bit
bringing together bits and pieces to make critical components, I then search for
seemingly disparate objects into a semi- GL̆HUHQWHYHQDELW other bits and pieces that will add to the
plausible whole toy. Steampunk toys give quirky RYHUDOOORRNRIWKHÀQLVKHGWR\
me the opportunity to do both. For the race car it was the old
I built the race car pictured here using compressor housing and the stainless
a variety of odds and ends. The engine discs, while for the three-wheeler it was
came from an old air compressor, the More than a toy the valve cover from an old motorcycle
wheels were turned out of wooden My second steampunk toy, the engine, which forms the central element.
shelving, destined to be burnt, and were construction of which I detail in this As for the race car, I built the wheels for
combined with a set of stainless discs that article, is an articulated three-wheeler, the trike out of Tasmanian oak salvaged
previously helped to support a network again built from odds and ends, including from timber shelving and incorporated
of shade cloths over a courtyard. The some aluminium off-cuts and bits of box the discs of discarded computer hard
headlights were made from a couple of section. Sticking to my mantra that these GULYHV DV KXEV 7KHLU FKURPH ÀQLVK
egg fryers and little brass taps, while the things should have some practical use imparts instant bling. (Incidentally, each

A steampunk race car reminiscent of the
grand old sports cars of the pre–World War
I era, when utilitarian designs based around
four wheels and an engine with a nod to
accommodating the driver, were the norm
hard drive has two small-but-powerful

magnets on plates that are perfect for
screwing to your shed wall to hold those
small tools you always seem to misplace
when you’re working.)
BMW donations
The head of the engine became the valve
cover mounted on a timber engine block.
The tail above the rear wheel is from
an air-intake manifold and a leftover
housing from a door lock that happened
WR ÀW SHUIHFWO\ LQVLGH LW 6RPH SODVWLF
and rubber parts were donated from a
dismantled BMW car. The novel steering
wheel was also made from a couple of the
discarded computer hard drives.
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of business as their size determined
WKH RYHUDOO VFDOH RI WKH ÀQLVKHG WR\ ,
did this by cutting out six rough timber
circles on my small bandsaw and gluing
WKHP WRJHWKHU LQ SDLUV , WKHQ WXUQHG
them down on my metal lathe to get a The next step involved creating a and my homemade sheet bender. An
uniform size and recessed their centres to simple T-bone chassis with a pivot in the inverted U-shaped section connects
accommodate the axles and the computer- middle made from two short sections the rear wheel to the chassis. Having
KDUGGULYHGLVFVDVKXEFDSV$FDQRIÁDW of steel pipe (see the accompanying FRQVWUXFWHGWKHEDVLFGHVLJQ,FRXOGWKHQ
black spray paint applied to the wooden diagram). move on to the best part of the project
wheels gives an acceptable approximation ,FODGWKHFKDVVLVE\VKDSLQJRIIFXWVRI — bringing the various bits together to
of rubber tyres. aluminium sheet using an old guillotine make the toy look plausible. `
The rolling chassis under construction The engine block taking shape

Above: Close up of the front end
Right: Trueing the wooden wheels for
the toy
Tools
you will need
• Hacksaw
• Guillotine and/or tin snips
• Welder
• Lathe (if you do not have access to
a lathe, you can use a drill press
to turn fairly good timber wheels.
Locate the roughed out wheel by
clamping it in the drill press chuck
and clamping a section of steel cut
off at an acute angle to the base
plate, gradually moving it in until
it takes a uniform skim off the
wheel. Alternatively, use a sander
to remove the high spots gradually,
until the wheel is round)
• Drill
• Sander
• Hole cutters
• Selection of screwdrivers and pliers
• Bandsaw or jigsaw
Front of the trike
Fitting the light lock housing and recessed it into the front
First, I constructed the rear mudguard of the engine block to hold it in the correct
and mounted the tailpiece on it. The air- place against the rubber trailer lamp. By
intake elbow was exactly the right size not gluing these pieces together, if either
to hold the chrome lock housing, behind light happens to fail in the future, it can Having constructed
which I situated a 12V halogen downlight. be replaced. the basic design I
I wired that to a switch hidden in one of Once the basic engine block was formed
could then move on
the rubber arms either side of the swivel it needed to be made a bit more believable
and located a small speaker jack under the by adding an exhaust stack on the left- to the best part of the
chassis so that the 12V transformer could hand side and by drilling out and inserting project — bringing
be located discreetly some distance from three Sodastream cartridges on the right. the various bits
the trike, or not used at all. After a few coats of copper-coloured spray
I unearthed an old rubber trailer paint were applied it was time to mount
together to make the
lamp assembly the exact size to house WKH EORFN DQG DWWDFK WKH SDUWV ÀQLVKLQJ toy look plausible
the deeply convex lens from one of the it off by mounting the valve cover on top
BMW’s broken headlights. To hide the 12V of an aluminium plate. To add a touch
halogen light, I used the second chrome of difference, I sourced some stainless

The essence of a steampunk vehicle, combining old, tested design features with flights of fancy to create a unique vehicle
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&'"%&! !' '
&! & % %& $ % & ! & %&*
!' ! ! !&!$% * Front light
%! & %&$ $ * &"" To power source
&$! !& % %$) & &!
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$($%&!!$&%&$ )! Transformer
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&% %%!&&$ %!$$%)
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'$%&%)#'*$+&& &$
! & &!*% !' ($ %'%%'* Wiring diagram for the trike

NO LONGER AN UPHILL STRUGGLE IT’S BEER-O’CLOCK SOMEWHERE
As green technology improves, the green solutions are Any layman can stroll down to the local and order a pint,
becoming the smart solutions. This is the case with The but few brew their own to taste. With the Grainfather
PowerSpout Smart Hydraulic Pump. Designed to pump water Connect all-in-one Grain Brewing System you can brew a
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daily pump visits. This pump has zero running costs thanks brewing experience. Recipes are easily created from scratch
to its high quality glass solar panels, which have a life of more and you can sync it to the Connect App on your mobile
than 25 years. With no building permit or electrician required, device and be guided through the entire brewing process
it’s easy to install yourself. It’s no surprise that more and more — allowing you to chuck it all in and simply relax until
people are embracing the technology that makes those higher you’re alerted when the next step is required! Electrically
cost fuel-powered pumps obsolete. powered and designed to be used indoors there is no need
for burners or hot plates; just plug it in and brew and there
Priced at $4999 + GST + delivery and made by really is no limit to the styles of beer you can make.
Ecoinnovation, a New Zealand-based renewable energy
company. Find out more at shop.powerspout.com/ The Grainfather
products/powerspout-shp-nz-complete. Connect all-
in-one Grain
Brewing System
is priced at $1350.
For further
information visit
grainfather.com
MINIATURE WONDERLAND
The largest model railway in the world is in Hamburg and
consists of 15,400m of track and takes up 1500m2, complete
with miniature Alps. Now, we’re not suggesting you embark
RQDQ\WKLQJRIWKDWVFDOHEXWLI\RXÀQGFUHDWLQJ\RXURZQ
little world enchanting, 040 Trains n Models is the place
to go, with an enormous range of high quality trains and
accessories by manufacturers such as Bachmann, Hornby,
DQG'DSROVFHQHU\E\6FHQLF7H[WXUHV3UHLVHUÀJXUHV
and Noch; and diecast models by Britains/ERTL, Siku and
Universal Hobbies.
Have a look at 040trainsnmodels.co.nz for the full list of
suppliers and products, or call 03 235 8498.
WORKING FOR THE CLAMPDOWN

Actually, there’s very little work with the quick-action lever
clamps from Teng Tools. The powerful bottom-mounted lever
bar makes it easy to apply the correct clamping force quickly
and comfortably, and it is easily unclamped with the quick-
release button. With bi-material grip on the handle, and
FRP material pads, it’s not hard on your hands or your work
surface. Available in 150, 300, 450, and 600mm. They’re
also on sale now until 28 February, priced between $29.90–
$44.60, saving you around 20 per cent off the suggested
retail price.
+HDGWRWHQJWRROVFRQ]WRÀQG\RXUQHDUHVW
stockist or email tengtools@tengtools.co.nz.
112 The Shed March/April 2018

YOU LEGEND
These super useful pants really are legends. The Yakka
Legends Pants feature heaps of handy pockets for all your
bits and pieces, extra reinforcement in areas likely to be
affected by high abrasion, and are extremely durable with
triple stitching in leg, front, and back crotch seams to
prevent tearing.
The Codura-reinforced knees takes the pressure off when
kneeling — and if you do a lot of it, there’s even space
to add knee pads. They’re also comfy; designed with a
UHOD[HGÀWDQGDUWLFXODWHGVKDSHWKH\PRYHZLWK\RXDQG
ÀWWKHVKDSHRI\RXUERG\
CUT-OFF WHEELS
THAT DON’T CUT OUT
Some cut-off wheels don’t go the distance, but Flexovit
are dedicated to long-lasting products. The Ultra Thin
Mega Inox Premium Cut-Off Wheels are excellent for
metal fabrication, with fast, clean cutting. The ultra-thin
premium-grade zirconia is designed to cut stainless steel,
alloy steels, and hard ferrous metals. They contain no
iron, sulphur, or chlorine and come as a pack of 25 in a USUALLY $84.95, READERS OF THE SHED CAN TAKE
reusable collector’s tin. ADVANTAGE OF YAK25% OFF KA LEGENDS PANTS.
For more info, contact the team at BOC on Enter the code PROMO25 at yakkashop.co.nz/legends-pant.
0800 111 333, or visit boc.co.nz.
THE GLOVE FOR ANY OCCASION

It’s getting pretty darn cold around the traps, so be prepared.
These waterproof winter gloves from Youngstown are
designed to not only to keep your hands toasty on frosty
mornings, but are also 100% waterproof and windproof,
thanks to the 3M Thinsulate lining, making them about
perfect for every job. Be it on the slopes or gripping the
handlebars, these gloves will continue to perform.
)RUPRUHLQIRRUWRSXUFKDVHWKHVHDQGRWKHUÁDPH
resistant, cut resistant, ARC rated, anti-vibration, high
visibility and touchscreen capable performance gloves,
visit youngstown.co.nz.
A METALWORKING NECESSITY
If you’re working with metal, this tool is indispensable. The
Halfco RNB40 Nut & Blind Riveter Set installs both nut and
blind rivets, joining sheet metals including aluminium, steel,
and stainless steel. Used in automotive projects, building, and
DIY, this is a versatile and unique tool. Aside from the hand-
operated twin-handle riveter, this 130-piece kit includes all the
bits and pieces you need, with rivet nut inserts (in sizes M5, M6,
M8, M10) and mandrels, blind rivets (3.2mm, 4.0mm, 4.8mm,
6.4mm), and a mandrel spanner, all in a compact carry case
Priced at $151.80 in store, or online.
Visit machineryhouse.co.nz/N001.
My business shed
FROZEN A WORKSHOP SALE IS TESTIMONY

TO A BUSINESS AND EQUIPMENT
FROM ANOTHER ERA
IN TIME
By Bob Hulme
Photographs: Bob Hulme and Adam Croy

A power press by John Heine,
recognized as one of the very best
brands of presses — solid and reliable
I
just love nosing around other people’s Winstone’s workshop in Auckland and
workshops to see what they are had the entrepreneurial spirit to take on
making and what gear they have, and I WKLVH[FLWLQJQHZÀHOG,WZDVLQWKH
recently just had the special opportunity
Those early years year his son Ian was born, that he took
to look at a manufacturing workshop that would have been a the plunge.
was about to be sold up and, as a bonus, struggle, with the As refrigeration was new and there
learn about its history. ZHUH QR FRXUVHV RU TXDOLÀFDWLRQV \HW
rewards coming later
Macdonald Refrigeration surely has a available he had to learn as he went. He
place in Auckland’s heritage as a pioneer developed connections with American
LQ LWV ÀHOG 7KH IDFWRU\ KDV EHHQ FORVHG brands such as Westinghouse and Beech
for some time now and it has been hard for servicing their products. Of course
for the family to let go of all the gear, History of Macdonald in those days most households still used
EXW LW LV ÀOOLQJ D ORW RI YDOXDEOH VSDFH Refrigeration a safe and refrigerators were regarded
Property leasing is the main focus for the Refrigeration was in its infancy when as a luxury, so there were very few
business now and prospective tenants Allan Macdonald decided to start his servicing specialists. Being involved
have been pushing them to make this own business servicing commercial and HDUO\LQDQ\ÀHOGLQLWVLQIDQF\LVDOZD\V
building available in the sought-after domestic refrigerators. He had completed an advantage, particularly when it has so
suburb of Grey Lynn in central Auckland. D ÀWWLQJ DQG WXUQLQJ DSSUHQWLFHVKLS DW PXFKSRWHQWLDO7KRVHHDUO\\HDUVZRXOG

Vacuum pump
Still in its original shipping crate is
an American-made Kinney vacuum
pump that Allan Macdonald bought
over 60 years ago for a project that he
apparently didn’t get around to. Still, it
might come in handy one day! You can
see in the photo that it came without
a motor due to the US voltage being
different to ours.
Macdonald was a manufacturer of fridges and freezers — this meant the company had to
import compressors, electric motors, and the refrigerant fluids
have been a struggle, with the rewards storage. Their factory had 70 employees
coming later. manufacturing domestic refrigerators as
The company initially worked from well as commercial units for butcher’s
premises at 1A Albany Road, Herne Bay, shops, hotels, hospitals, etc. Many of
Auckland, concentrating on service these were custom-made units, such
work, but with the decision to add as refrigerated window displays for
manufacturing to the business, it moved EXWFKHU·VDQGÀVKVKRSV
to Weld Street in nearby Freemans Bay.
Don’t plan on looking Weld Street up Importing materials
though, as it no longer exists. It was dug Being a manufacturer also meant
up and is now covered with buildings. being an importer of the materials
It was a link between Napier and needed to build the units. These
Union Streets. At that time there were included compressors, electric motors,
neighbours, including the warehouses DQG WKH UHIULJHUDQW ÁXLGV 2UJDQL]LQJ
of Farmers Trading Co and Walker and shipments had to be coordinated with
Hall. There was also a row of small SURGXFWLRQ 2IWHQ JRRGV ZRXOG EH
houses that the Macdonalds bought VKLSSHG WR $XVWUDOLD ÀUVW WKHQ RQ
as they became available to use for to New Zealand. With labour strikes

Lathes
There was a row of three lathes —
two Colchesters and a Logan. Now,
Colchester has always been a good
brand and either of those would be
welcome in anyone’s home workshop.
They may be old, but the quality of
those British-made machine tools
lives on. The Logan would make a
great replacement for a Myford. I am
thinking about my own experience here
when I bought a Myford for my home
workshop, but quickly found it was
too small for most of the jobs I wanted
to do. A Logan is a bit bigger, but not
so big that workshop space is severely
tested. Logans were never as rigid as
Colchesters yet they filled that gap
between Myford size and the heavier
floor-standing lathes really well.
Famous clients
One of Macdonald’s customers was
Adams Bruce, who had a chain of
shops that served delicious ice cream,
chocolates, and biscuits — at least they
are the things I remember buying there
as a kid. Each shop had a freezer for the
ice cream of course, but Ian recalls that
the Adams Bruce ice-cream factory was in
Collingwood Street, in Freemans Bay, and
ice cream was sent to the Bruce shops on
New Zealand Rail (NZR) Road Services
buses. This was achieved by packing the
ice cream in round steel cylinders that
had a glycol hold-over tank with dry ice
underneath — all wrapped in an insulated
canvas jacket. Before the advent of courier
companies most packages were handled
by NZR Road Services buses.
A sturdy Logan metalworking lathe After hassles with the Auckland City
Council rezoning the area where the factory
at docks on both sides of the Tasman were methyl chloride and sulphur dioxide. was in Freemans Bay and the council
occurring from time to time the With refrigeration becoming more ÁLSÁRSSLQJ RQ WKDW ]RQLQJ 0DFGRQDOG
coordination was often frustrating. An popular, especially for retail businesses, Refrigeration decided to move. In 1968, it
understanding bank manager was vital the need to travel outside Auckland to moved to a new factory the company built
then, just as is today. service customers was vital. Servicemen in Richmond Road, Grey Lynn. The site
Imported refrigerant gas was typically from Macdonald were sent as far north was purchased from the well-known local
shipped in tall cylinders, which were then as Kaitaia (Ian tells me that he once went Warnoch family, who had a soap factory
decanted into smaller ones that were there and back in a day to do a repair next door, on a handshake deal — totally
easier for servicemen to handle on site. job) and as far south as Hastings and unheard of today. Staff numbers at this
Typical refrigerants in those early days Palmerston North. time were 42. `

Macdonald Refrigeration has a fine selection
of lathes. Here two Colchester lathes
bookend a Logan
Fraser and Ian Macdonald, grandson and son,

respectively, of the business founder, Allan Macdonald,
who started the refrigeration business in 1938

Metalworking machines
This Philips arc welder uses glass

vacuum tubes for power rectification
I felt like a kid in a lolly shop wandering or DC welding, and on closer inspection
around the Macdonald factory. There was I could see large, old glass vacuum tubes
such a range of metalworking machines inside, presumably for rectifying the power.
that I didn’t know where to start. There I was told that the welds it produced were
were folders, guillotines, a press brake, wonderful and it is still in working order.
and power presses. Even a trusty Dyco drill Smooth finish and deep penetration were
press (brands such as Dyco and Tanner are typical of the output. I have never seen one
very desirable today as they are solid and like this before — amazing.
reliable). I was especially interested in an All the machinery has obviously been kept Even the fly press
was a John Heine!
old Philips arc welder. It can be set for AC in good condition and some appeared to
have been modified to improve output. I

noticed a guillotine driven by an old, but
solid, electric motor and looked closer to
see that it was John Heine brand — the
same as the two power presses that were
there. Heine is recognized as one of the
very best brands of presses. I have worked
with this brand of power presses and they
are so solid and reliable that they seem to
keep going forever. Even their fly press was
a John Heine!
Edwards is another brand that was
once revered as a maker of top-quality
equipment and Macdonald had an
Edwards folder. This was a fine example
of a folder made with a cast-iron frame,
Large fabricated frame guillotine
meaning that it has great rigidity.

The famous John Heine
brand featured large in this
Spot welder manufacturing shed. Here is a
John Heine guillotine
With labour strikes at

docks on both sides of
the Tasman occurring
from time to time the
coordination was
often frustrating
There was another folder of more recent

manufacture with a fabricated (welded)
frame. I don’t want to give fabricated folders
a bad rap as they do work quite well, but my
pick would be the old Edwards.
Another Edwards machine was a foot-
treadle-operated small guillotine — ideal
for small jobs like chamfering corners on
sheet-metal items. Yet another Edwards
machine was the press brake. No, it doesn’t
break things, it bends them. The top blade
moves down onto a fixed die block to
bend the sheet metal between the blade
and the die block. By changing the blade
and the die-block shape (the die block can
be rotated to bring different forms to play) it
is possible to create different bends or even
An Edwards press brake
radiused shapes.

One customer felt that, when it was popular to buy a whole beast
when she passed away,
the fridge she had loved and store it in the home freezer.
so much should go back to Many Aucklanders will recall butchers
the company that made it,
Macdonald Refrigeration like Albany Meats, which sold wholesale
and in bulk to the public. Ian tells me
that the butcher would sell direct from
the factory and on the weekends people
would often arrive with an animal carcass
in the back of their car needing a freezer
right away. They sold as many as 27 chest
freezers per day at the height of that era.
However, commercial refrigeration
was seen as the backbone of the business
She followed the
and eventually Macdonald concentrated
truck in her car to solely on that market.
make sure that her
beloved red fridge did Manufacturing in
New Zealand
not get scratched Most of my own career has been in
manufacturing in New Zealand and I am
saddened to see so many businesses close
their workshops and instead become
Every fridge has a story a model a relative of mine had had years importers of products manufactured in
Ì saw several examples of the company’s ago. This also had been bequeathed to low-cost countries. It seems wrong that
domestic refrigerators in storage together WKH0DFGRQDOGVE\DVDWLVÀHGFXVWRPHU we allow our innovative Kiwi companies
with factory equipment when I visited. Inspection showed that over the course of to suffer against imports of items from
Some had a story behind them. I saw a its life, all that it had needed was a new countries where their governments
red-coloured fridge and a matching chest V-belt for the drive from the motor to the probably subsidize them so that they
freezer. Ian related the story of the lady compressor. Every other part was exactly can overrun the competition. However,
who bought the red fridge new from them as it was when bought new. Amazing! I am heartened by the stories I do hear
and when it needed to come to the factory of New Zealand manufacturers making
to be serviced, she followed the truck in Fill those freezers a go of it even in this climate. Just last
her car to make sure that her beloved red The production of domestic refrigerators week I heard of a local manufacturer
fridge did not get scratched. When she was eventually dropped as competition making rivets for export to China and
passed away some years later the fridge stepped up from other companies, as DQRWKHUPDNLQJÀVKLQJJHDUDQGVHOOLQJ
and freezer came back addressed to Fraser well as imported product, but Macdonald successfully in many other countries.
Macdonald, Ian’s son, who had assisted the established a niche producing chest Come on, Kiwis, you can make stuff
lady when her fridge had needed remedial IUHH]HUV DQG ZDV D SLRQHHU LQ WKH ÀHOG on home turf and if you can’t think of
work. He had given such good service and However, the company was approached something clever to make just yet, at
she loved that fridge so much that she felt by a competitor, Bonaire, which also made least try buying locally made things in
it should go back to the company. chest freezers, and was offered a deal to the meantime — the standard of living
Another old-timer was a double-door sell its products. The economics stacked for all of us will improve. Ahh, I feel
fridge that I recognized as one similar to up so they did the deal. This was a time better now I’ve had my rant.
Solid bench
It is not every day that you come across
such a large wooden work bench made
entirely from kauri. This one has seen
some work and I did not appreciate the
timber until Ian Macdonald pointed it
out to me. I hope that someone buys
it to keep as a work bench, as I think it
would be a shame to pull it apart just to
sell off the timber.

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Biggles of
Oamaru By Jim Hopkins
N
o question, it was déja view. The got drilled and grilled by a particularly SUHWW\FUD]\ÀOPZKLFKWKH\VKRZHGDW
moment I saw the building I knew FXUPXGJHRQO\ ÁLJKW VHUJHDQW 0D\EH WKHLUSUHWW\FUD]\ÀQDOGLQQHU7KDWOHG
that I’d been there before, and he’d had a bad day; maybe he was a bad to an invitation to speak at the mess at
that recollection triggered a rush of person; maybe he just had a tough way of Ohakea — and my second great RNZAF
other memories, most marvellous, some saying true things. Whatever the reason, disappointment.
bittersweet. he minced no words as he strode along, “What would your fee be?” an
$VWKHEXLOGLQJZDVWKHROGRIÀFHU·VPHVV questioning each cadet in turn. instructor asked.
at Wigram, where I’d been the after-dinner “Why are you here?” he bellowed. “Fee?” I said, sensing a unique
speaker one anxious evening, and Wigram ´, ZDQW WR Á\ 9DPSLUHV 6LUµ , EROGO\ opportunity. “Ummm, err … how about
ZDV P\ ÀUVW ÀHOG RI GUHDPV EDFN LQ WKH replied. DÁLJKWLQD6N\KDZN"µ
GD\V RI V G $LUÀ[ PRGHOV DQG YLVLRQV “Vampires?” he snorted. “With glasses Well, the deal was seemingly done, the
of Vampires — de Havilland Vampires, like that? Milk-bottle bottoms? You’re speech duly delivered and, next morning,
you understand, the kind the Royal GUHDPLQJµ %LJJOHV·MXLFHVÁRZLQJ,SROLWHO\LQTXLUHG
1HZ=HDODQG$LU)RUFH51=$)ÁHZ 6R WKH DLU IRUFH ORVW LWV EHVW %LJJOHV what preparation was needed for my A-4
$QGVLQFHOLWWOH-LPÀJKWHUSLORWVXSUHPH ever and I found other things to do on ÁLJKW 7KHUH ZHUH HPEDUUDVVHG ORRNV
(in the cockpit of his imagination), Wednesdays. Yet I’ve remained connected DQGVKXIÁHGIHHW
ZDQWHGWRÁ\WKHPWRRKHJRWWKH%UDVVR with Wigram through the years. I’ve “Oh, we thought you were joking.
polished the buttons, pressed the sky blue ÁRZQJOLGHUVWKHUHWDNHQ\RXQJVRQ7RP We’re not allowed to take civilians up for
tunic, and turned up at No. 9 hangar up in the Catalina Preservation Society’s MR\ULGHVµ%XWWKH\GLGOHWPHVLWLQWKH
Wigram every Wednesday to parade as 3%<$ HDFK RI XV SHHULQJ H[FLWHGO\ RXW Skyhawk’s tiny cockpit and explained
a proud member of No. 17 Squadron, of the massive observation blisters at the WKDW , ZDV TXLWH OXFN\ QRW WR EH Á\LQJ
Air Training Corps (ATC). rear of the fuselage, trying to spot our because, if I’d had to eject, I’d have
Wigram was still an airbase then, house; I’ve been a passenger in a Convair probably had my kneecaps ripped off by
hangars full of aircraft — Mustangs, 444 and a DC-3, each heading through the the control panel on the way out. That
Devons, and a host of Harvards, lined alps to Westport (on separate occasions, of had happened, they said, to tall people.
up in front of the control tower, canopies course); and, one Easter, had an absolutely It all came roaring back, faster than
RSHQÁXRURWDLOVUHGDZDLWLQJWKHQH[W IDQWDVWLF ÁLJKW IURP :LJUDP WR WKH the speed of sound, when I saw that
tranche of trainees. Omaka air show (and back) in ZK AKY, imposing 1938 building once again.
Which would soon include me. That the Croydon Aviation Trust’s wonderful 7KH\GRVD\\RXUOLIHÁDVKHVEHIRUH\RXU
ZDVFHUWDLQ,ZDVJRLQJWREHDÀJKWHU ex–National Airways Corporation (NAC) H\HVZKHQ\RX·UHFKHFNLQJRXW%XWPLQH
SLORW ORRSLQJ GLYLQJ GRJÀJKWLQJ Dominie biplane. I remember our pilot, ÁDVKHGZKHQ,ZDVFKHFNLQJLQ<RXVHH
ÁDVKLQJ VLOYHU WKURXJK WKH VN\ 7KDW·V Ryan Southam, circling low so we could :LJUDP·V ROG RIÀFHU·V PHVV LVQ·W D PHVV
why I’d joined the ATC and endured all see the dolphins off Kaikoura and feeling any more. It’s an Airbnb place, housing
the ‘ten-shunning’, quick marching, and sorry for everyone who wasn’t on that tourists, not recruits, single rooms just
square bashing, our footsteps echoing plane that day. DQLJKW³QRHQVXLWHRUWHOO\PLQG
off the walls in the cavernous dim of the %DFN RQ WKH JURXQG EHIRUH :LJUDP but who gives a toss when just being
empty hangar. closed, a group of Skyhawk jocks on an there brings back to life some of the best
Then, one chill, mid-winter night, we instructor’s course asked me to make a times ever, free of charge?

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centre punch T30, T40, T45, T50 3/16, 1/4, 5/16, 3/18" • Chrome vanadium steel
• Ø22mm ergonomic • Chrome vanadium steel • Chrome vanadium steel • Adjustable 3 detent
plastic body • Adjustable 3 detent • Adjustable 3 detent positions on T-bar handle
• Ø37mm curved end positions on T-bar handle positions on T-bar handle • Free spinning rotating
Order Code: P368
• Free spinning • Free spinning rotating handle
rotating handle handle
$
25.30 Order Code: H822 Order Code: H821 Order Code: H820
$
96.60 $
96.60 $
96.60
MKP-2 RNB40
PP-10HD - Workshop Mobile Knee Pads BD-325 Nut & Blind Riveter Set
Hydraulic Press • 6 x oil resistant swivel wheels
Bench Drill • 130 piece kit suitable for sheet
• 10 Tonne • Durable high impact plastic frame • 16mm drill capacity aluminium, steel & stainless
• Bench mount • Built-in tool storage tray • 2MT spindle • Aluminium rivet nut inserts:
• 180mm ram stroke • 113kg load capacity • 12 spindle speeds M5, M6, M8,
• Adjustable ram position M10 (10ea size)
• Swivel & tilt table
Order Code: P141 • Blind aluminium rivets:
• 1hp, 240V motor Ø3.2, Ø4.0, Ø4.8,
$
368 Order Code: D590 Ø6.4mm (20ea size)
• Mandrel spanner &
$
368 blow mould case
Order Code: N001
151.80
Order Code: A3615
$
LT-500 $
39.10
Hydraulic Lifter Trolley
• 500kg load capacity
• 810 x 500mm table
• 295-780mm BF-20LV - Mill Drill Geared
table height BP-310
Wood Band Saw DC-3 & Tilting Head
Order Code: J050 • 305 x 165mm capacity Dust Collector • Electronic infinitely variable speed
$
379.50 • 1200 cfm - LPHV system • (X) 480mm (Y) 175mm (Z) 280mm
• Cast iron table tilts 45º
• 5 Micron fine filter bag • Dovetail column
• 2 x blade speeds
• Portable on wheels • 2 speed gearbox
• LED lighting
• 1.5kW/2hp, • Head tilts ±90°
• 0.75kW / 1hp 240V
240V motor • 850W, 240V
Order Code: W952
Order Code: W394
759
Order Code: M650
$
CS-275
$
437 $
1,978
Cold Saw
• 90 x 50mm capacity
• Ø275 x 32mm blade os-58 - Oscillating
• 42rpm blade speed
• 1.3hp 240V motor Vertical Bobbin Sander
• 1/2", 3/4", 1", 1-1/2", 2" & 3"
Order Code: S816
• 370 x 290mm cast iron table
$
1,782.50 •
•
Rotating & oscillating
450W / 240V motor
Order Code: W843
$
322
AL-320G
9(
BS-5V Bench Lathe
:(+$ Swivel Head Band Saw • 320 x 600mm
(5 ,*+7 turning capacity
7+ • Compact design, only 23kg
) 25 • 38mm bore,
722/ • 130 x 125mm (W x H) rectangle
12 spindle speeds
2% • 30-80mpm variable speed
<285- • Swivel head to 60º • Geared headstock ST-320G
• 1.3hp, 240V motor • 1hp, 240V motor Lathe Stand
Order Code: B004 Order Code: L141 Order Code: L142
$
687.70 2,852
$ $
368
- AMY
Staff Member
Ceelebrratinng 10 yeaars of Bussinesss!

Machine
eryhouse settiing
g the stan
nda
ard for quality and value
UNIQUE PROMO CODE

01_THE_SHED_190218
www.machineryhouse.co.nz/SHED118
SHED118 2 Waiouru Road, East Tamaki 2013
ONLINE OR INSTORE! Ph: (09) 2717 234
Specifications & prices are subject to change without notification. All prices include GST and valid until 31-03-18
METALEX
p r o t e c t & p reserve
Metalex, on guard to keep your timber safe.

If you are cutting, scarfing, drilling or notching treated timber you are weakening the treatment
envelope and the strength and lifespan of your timber. Apply Metalex to protect and preserve
your timber this summer.

2018-Mar-Apr The Shed

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PURRFECT

Year Warranty Red List Free Appraisal No.797 [2012]

* Terms & conditions apply

Some things just Odelia Schaare

make sense STAFF PHOTOGRAPHER

The Shed 77 March/April 2018 1

Boardwalk racing motorcycle Oamaru Steam & Rail

2 The Shed 77 March/April 2018

Every issue Fires Part 4

4 The Shed 77 March/April 2018

The Shed 77 March/April 2018 5

6 The Shed 77 March/April 2018

saw is an Alaskan Mill Mark III. With

Old walnut myths

The Shed 77 March/April 2018 7

Dave uses a standard 3.6m aluminium

8 The Shed 77 March/April 2018

The Shed 77 March/April 2018 9

Dave’s guide to cutting huge beams with a chainsaw!

10 The Shed 77 March/April 2018

Mill your own

O VER 17,000 L UCASMILLS S OLD W ORLDWIDE!

Kreg Jig K5 Pocket Hole Jig

QUICK-RELEASE KR-K5MS $349 inc GST (Pictured)

12 The Shed 77 March/April 2018

up his hammer to resurrect the mill and

The Shed 77 March/April 2018 13

“It can be a challenge.

14 The Shed 77 March/April 2018

Above right: Lloyd’s very-old-but-still-very-effective sanding belt

Right: All the Knowles’ machines are hooked up to extractors, which

The Shed 77 March/April 2018 15

Right: Lloyd insists timber needs air to dry

16 The Shed 77 March/April 2018

scale of the competition was amazing. It

Going for gold

18 The Shed 77 March/April 2018

The Shed 77 March/April 2018 19

The winner of the Letter of the Month

20 The Shed 77 March/April 2018

Drawing water in, keeping leaves out

The new Marley Curve™ combines sleek, sophisticated design

 Cleaner water into your tank improves water quality and

 Reduces chance of your drains blocking

 Quick release upper body for easy maintenance

Water when you need it

The new Marley Twist®, with an easy twist on-off function,

 Can ﬁll a 300 litre tank in an hour*

 Positive impact on the environment through reduced mains

 Direct connection to standard hose ﬁttings

Curve™ and Twist® are available in a range of colours

White Grey Friars® Ironsand® Black Copper Titanium

* See Marley.co.nz for details.

22 The Shed 77 March/April 2018

The Shed 77 March/April 2018 23

Left: The rainhead ﬁtting with both

Below left: The stuff you don’t really

24 The Shed 77 March/April 2018

holds 35,000kg (35 tonnes) of water

Cleaner water into your tank improves water quality and

Reduces chance of your drains blocking

Quick release upper body for easy maintenance

Can ﬁll a 300 litre tank in an hour*

Positive impact on the environment through reduced mains

Direct connection to standard hose ﬁttings

Prevents Dry Tank Syndrome

"!! !