My top maker materials - 16 gauge, 1-inch square steel tube
Part 1 of a new limited series
As a maker, I gravitate towards a specific list of raw materials for my builds. These foundations - the building blocks of all I create - offer a variety of benefits I’ve grown to expect and trust. These are indispensable commodities for a generalist maker (like me), and I want to share them with you.
This series will not simply be broad-stroke stories on why I like “so-and-so stuff." Instead, I aim to share what specific types of material I use - particular species, if you will - and give a few pointers on what you'll need to know if you choose to use these too.
Today, for example, is more than "steel” alone. It's "16 gauge, 1-inch square steel tube.” I'll share my reasoning and explain why this type of steel product is also a good material for anyone else wanting to work in metal. I’ll even share basic costs to help you decide if and when to jump in yourself.
Now, on to today's featured material.
16 gauge, 1-inch square steel tube
Tools I use: MIG welder, angle grinder, portable metal bandsaw, black oxide HSS drills, speed square for marking cuts, and all the needed PPE.
Cost of entry: about $700-$1000, depending on options. Get a decent welder (I have a Hobart Handler 125, a great entry-level model) plus a welding gas tank and regulator. Other tools required are often already in your shop or can be purchased second hand. The steel in this size and format is less than $2 per foot.
An oft-sited thing about steel - it is the king of all maker materials.
Found in everything from buildings to bridges, cars to rocket ships, things of substance are made of steel. And it's no wonder - steel has a strength-to-weight-to-workability ratio unparalleled in modern design and manufacturing. Sure other materials are stronger or lighter, but metals like titanium are challenging to work without specialized, often industrial, equipment. And they're expensive. Steel works easily with affordable garage-shop-quality tools, and recycled stock is remarkably cheap and relatively environmentally friendly.
For years I hesitated to work with steel. I don't have a welder. I can't afford a welder. I don't know how to weld! But welders, as alluded to above, are surprisingly affordable (a decent MIG can be had for $200-$400). And learning to weld is nowhere near as scary as I once thought (unlike the table saw; see future installments).
Nevertheless, welding is intimidating, if only by the looks of it. So if you are hesitant to self-learn, many classes are available at local community colleges and maker spaces. Me? I bought my welder from Tractor Supply, picked up some scrap steel at a local recycler, and started making sparks.
I did watch a few YouTube videos and consulted with a friend who is an accomplished welder (thanks again, Lizzy!), and then I jumped in. The process smoothed out quickly for me, and I now make a passable weld and build things that stay together. But there is an art to it, and I am far from accomplished. So I keep looking for novel applications to hone my skills.
The payoff? With steel, it's an incredibly durable build with a high dose of satisfaction. Knowing I melted raw steel together to create a thing. Talk about empowering.
As for my specific steel of choice, the "one inch" is self-explanatory - this steel is in tube form, square in cross-section. It's precisely 1 inch across, making designing, measuring, and working with it easy.
And my preferred thickness of 16 gauge is about 0.065 inches thick (about a sixteenth of an inch or roughly 1.7 mm). The best part about this size and gauge steel tube is that a finished design often weighs less than a comparably designed object from wood.
You read that correctly - tubular steel construction is often lighter than wood.
This stuff weighs only about 0.7 to 0.8 pounds per foot; a foot of 2x4 lumber weighs almost a pound or more per foot - and is far bulkier. Despite the thin walls and overall lightness of 16-gauge square tube, the geometry makes it quite rigid. So with a bit of thought and some appropriate spacing of lengths and supports, steel works wonders in compact spaces and broad applications alike.
I made my welding cart from the stuff. Same with the door and perches for my chicken coop. And I'm planning a compact shelving unit for my utility room. The possibilities are great with 16-gauge 1-inch square tube steel.
Another reason this is my favored steel maker product is that it's easy to cut - even with a hack saw. But I often use power tools to get the job done fast. An inexpensive angle grinder with a cutoff wheel rips through 16 gauge tube like a stick of butter (which is, oddly enough, about the same shape). And for a cleaner cut, I occasionally use a portable bandsaw. For holes, a quality set of drill bits is well worth the upfront cost, along with a decent drill. I do have some cheap bits too, and for hogging out a hole, these disposable ones are fine. But when a hole needs to be precise, I reach for the top-shelf drills.
Lining up and measuring steel tube for cutting and welding requires a square, and my favorite is a speed square (one of those triangle-shaped ones often used in construction). I mark the tube in various ways, but most often with a pencil, although there are scribes and other instruments available. If I am in a low-light area, I occasionally mark with a Sharpie so I can see the line better, although the broad stroke it creates can make exact cuts more difficult.
Personal protective equipment (PPE) is a must when working with steel. Hearing, eyes, hands, and lungs are all exposed when welding and grinding metal, so invest in good PPE to keep your irreplaceable faculties intact.
Like many things, learning to use steel takes some practice. But the only way to get there is to get your hands dirty and try. Honestly, I wish I had started welding years ago. It’s far easier than I feared, and it’s way more fun than I ever imagined. Of all the maker skills I've learned, steel has opened up more possibilities than any other material.
As I said, it's an empowering feeling to melt two pieces of steel together. And anyone interested in making with metal can do it. If you’re interested, I highly recommend using 16 gauge 1-inch square steel tube. It’s light but strong, easy to cut and weld, and economical. And it makes for solid builds that you’ll be proud to share with others.
Until next time.
JRC
Great idea for a series - someday I would like to try welding. Not sure what for...
My #1 takeaway from this John - you have a chicken coop! Who knew, besides your immediate neighbors?