welding

Tool School: A Quicker Way to Cut Steel

Learn how to weild a plasma cutter like a pro and you can slice through steel like butter

Building things from metal can seem intimidating—metal just feels so much more permanent than, say, wood, and with the all the sparks and pressurized cylinders, it seems like just a matter of time before you blow up your shop. But once you know your way around a few key tools, you'll be amazed at how simple metalwork can be. Case in point: the plasma cutter. This small, relatively inexpensive machine has one dial, no cumbersome gas tanks, and can zip through any conductive material faster than a jigsaw through pine. It's also basically a sci-fi machine made real (c'mon, it slices through steel with hafnium and air!). And since they're for sale in most big-box home stores, you can even put one on your X-mas list. Master this, and your metal creations can take on just about any shape you want.

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Tool School: Break Out the Torch

The basics behind cutting steel with flame

MIG welders and plasma cutters might carry more cache, but serious metal cred comes from the mastery of a simple flame. The oxy-acetylene torch setup is one of the most affordable versatile tools in any shop. With it, a competent operator can heat, weld, braze, silver-solder, and cut. We've used it for all of the above, but it's most often used to heat steel for bending and to cut. Cutting with the torch is so incredibly simple and cost-effective compared to plasma cutting— especially for thicker materials—that it cannot be ignored. Fortunately, it's also not that hard to learn. Here's a quick primer to the tool every metal shop should have.

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Learn How to Do Anything with Netflix for DIY Nerds

From lock-picking to building veggie-oil cars, Smartflix gets you up to speed

Almost four years ago I swapped out my fancy lad IT job in New York City for a 100 percent DIY lifestyle in Truth or Consequences, New Mexico. The only problem was that I didn't have any building skills. Fortunately, I came across an advertisement for Smartflix: A DVD-rental service sorta like Netflix except all the videos are how-tos. The library covers everything from how to silkscreen a t-shirt to building energy efficient homes. At only $10 per disc rental (a few are more) and over 6,200 titles this service saved my DIY life. Follow the jump to check out my favorite titles.

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Green Dream

Welding, Part One: Gear Selection


My welding hobby started shortly after I got a bid for a steel staircase. As with everything, the money always causes me to do the Carnett calculation:

  • How much is the equipment?
  • How much is the material?
  • How much did that guy say he wanted?
  • How much can I save?

Then I run off to buy the gear.

This of course leaves out the skill to do any of these things -- but the Carnett calculation includes the discovery phase, where I make all my mistakes, ask just about anyone for help, and somehow come out on the other side a more skilled operator. And 50 percent of the time, I really do save money.

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Gray Matter

Bacon: the Other White Heat

You know bacon is delicious, but did you know it contains enough energy to melt metal?

I recently committed myself to the goal, before the weekend was out, of creating a device entirely from bacon and using it to cut a steel pan in half. My initial attempts were failures, but I knew success was within reach when I was able to ignite and melt the pan using seven beef sticks and a cucumber.

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December 2009: Best of What's New

In our December issue, Popular Science names the 100 best innovations of the year: bombproof wallpaper, self-parking cars, the fastest helicopter, and 97 more. Plus inventor profiles and videos.

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