How to Build a Whirligig Out of Metal

Make a whirligig out of metal using pattern from different sources and making it out of metal.

Difficulty: Moderate

Instructions

Things You'll Need:

• Pattern
• Metal
• Metal Dowels
• Saw
• Drill
• Welder(optional)
• Screw Drivers
• Screws
• Finish of Choice

1. Draw, download or purchase a pattern for a whirligig you would like to make. It does not have to be for metal. It could be a pattern for wood.
   Make an extra copy so you can refer back to it as you put it together with the instructions.

2. Print or copy pattern onto a piece of paper.

3. Take your metal that is to be used. Large parts should be made from on sheet of metal, unless you plan to weld them together. If you weld them together than you should do this now.

4. Spray some tack glue to the back of the pattern.
   
   Wait till it sets to the adhesion consistent of tape and apply to the metal.

5. Use your saw of choice and cut out parts that are on your patterns.

6. Now the fun part is to remove the pattern from all the metal pieces.
   Use a method of choice. Get all the glue off the metal so your finish will look as best as it can be and so you don't have your metal parts wanting to stick to you as you work.( Be careful with the edges of the metal, the are sharp at this point!!

7. After you have your parts cleaned. Chamfer the edges so they are not razor sharp.

8. Look at your instructions and read over them. When they say apply glue you can either weld them together or screw them together,
   At this point you should drill and countersink your holes for screws if you are using them.
   I would say that if you are using screws that you should tap the holes for the screws.

9. Now that the holes are drilled. Lets move on. Follow your instructions on assembly. If you are welding your pieces tack them together temporally for now. Assemble your whirligig.

10. Now check to make sure every thing works properly. You may have to do a little modifying now if you whirligig does not work right.
    
    Like if you are making a bird whirligig you may have to modify the wing so they are balanced and spin and not just rock back and forth.
    
    Weld your parts up and check your balance again.

11. Follow the instructions and apply your finish of choice.

Tips & Warnings

• HINT
• If you would like a smooth finish (no weld or screws showing) you could put a thin layer of automotive filler and sand smooth. Prime with filler primer and finish of choice. (make sure the paints are compatible)