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Homemade Reduced Weight Bar

Al Smith

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Jon1212

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Knock out holes in electrical panel boxes, etc for romex connectors/conduit, etc.
Yeah, I figured it was for sheet type material, and didn't seem like a good idea on bar stock.

^^^Truth. A bar would be a bad idea for that.

Yep. It would be a good way to lose an eye, or two.
 

Philbert

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Back to JB Weld - we used to mix 'micro balloons' into epoxy, when building kayaks, to make a lighter weight filler material.

I would also think about 'P-tex' - the drip plastic candles we used to use to repair skis. Kind of like those 3-D printer materials.

Philbert
 

Wagnerwerks

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Back to JB Weld - we used to mix 'micro balloons' into epoxy, when building kayaks, to make a lighter weight filler material.

I would also think about 'P-tex' - the drip plastic candles we used to use to repair skis. Kind of like those 3-D printer materials.

Philbert
What about mixing in some full size balloons?
 

Jon1212

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Please get a small round magnet and tell us more about what lies below the filler. Swiss cheese perhaps?
TIA
That ain't "filler". Oregon uses two thin aluminum pieces that are riveted through an inner tab rim in the cutout.

PS. Do you still have that Shindaiwa?
 

Lightning Performance

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Yea. Wife made plans this week for her vay cay that included me. I get some forum time in :)
I'll send it Friday or next week. Somebody else needed sumtin to. damn if I can remember anything this with all that is going on.
 

Wagnerwerks

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I'd use aluminum inserts and then do 3 or 4 recessed rivets around the outside. You could dress the edges with jb then and sand flush.
 

Philbert

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Cut a keyway / recess all around the inside of each hole, and around each aluminum slug. Fill the slot with epoxy, or leave a small hole to pour molten solder. The solder would let you remove the slugs, if needed.

Philbert
 
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