In my desire to use up scraps of this and that I came across a few sections of white painted steel tube.

Thought maybe I could use one section as a support post for a small table idea. 

Challenge is to reshape the end of the tube so it won't/can't turn when inserted into a CNC cut pocket. 

I'm going to see if can press the tube into a form  I CNC cut to reshape the end from a circle to a hexagon cross section.

Two of these cut from HDPE, pressed together in my bench vise with the pipe end in between them. 

I used Aspire's features to make sure the circumference of the pipe is the same from circle to hex. 

I also plan on inserting this wood plug with an embedded square nut in the side.  Theory is that if the plug is trapped in the pipe I can pull the plug and pipe snug with a bolt.

Toolpaths created for form halves and rotary plug.   As I get them cut and try them out I'll post the results. 

4D

 

Edited March 19, 20251 yr by 4DThinker

Forms turn out good.

Forms didn't struggle to reshape the pipe end.

Rotary plug ended up too small.  Need to re-measure everything and try again.  Or give up on the plug idea and instead run a length of all thread (which I have on hand) through the pipe and bolt down each end. 

4D

Took two tries. First one too tight. Hex pocket, 1/2" deep. 1 degree slope using the fluting toolpath and an array of very short lines around the perimeter.
Pipe end fits tight, and gets tighter as it gets deeper into the pocket.
 

This block will be the center of the table base. I'll use the same toolpaths on the underside of the table top. Center hole is just a hair larger than 1/4" for 1/4-20 all-thread to pass though. Recess for washer and lock nut on the other side.
4D

The wood block shown in the previous post cracked when I tightened up the all thread between top and this block.  I made a new one but didn't taper the hex hole.  Seems stiff enough.  Now working on the base parts.  4 strips of wood to surround the wood block.  CNC cut tapered halving joints (that wedge together) to interlock them. Like this render, but when assembled will get a rounded top surface to mimic the underside of the wood top. 

They will run diagonally from opposing corners with one on each side of that center block. 

4D

This is the parts all assembled.   The base will get some refinement before finish gets applies.  Rounding/tapering down from center to ends to vaguely mirror the underside curve of the table top. 

All-thread through the pipe from table top to center block. Pipe deformed to a hex shape on both ends so the base and top relationship doesn't change accidently. 

I had to do a little thinning and trimming of the base boards after the CNC was done cutting the slots.  Tape measure and my eyes aren't as accurate apparently than my digital caliper is.   Snuck up on the thickness using my drum sander.  Snuck up on the width of the boards at my mini jointer.  1/64" at a time. 

Boards slip together easily until the last 1/8" or so,  Pressed them snug with my bench vise. Center block had to be trimmed a tiny bit. Center area of the base is exactly 1.5" x 1.5".  The block was a few thousandths too big to fit.   Disk sander handle that.  No glue yet, but all the base parts will eventually be glued together. 

4D

Refined base.  Drew a profile arc line that when crossing the intersecting slats was at 3 degrees.  The used my 3D tapered end mill to cut the profile on each piece.

Now the arcs blend at the intersections.  3 degree edges across 3 degree edges.  Lessens the visual mass of the base.  Mitered corners are below the corners of the top above.  

Next is to stain the wood parts.  Base parts were scraps from an outdoor swing I refurbished.  A mix of different colors and densities.  Hope is to stain them so they generally look the same color as the stain top will.  Cherry stain. Whatever clear top finish I have enough of. 

4D

Cool project 4D. Quite creative and resourceful.

4 minutes ago, Grandpadave52 said:

Cool project 4D. Quite creative and resourceful.

Thanks.  The part I like least is the white pipe.  Having thoughts of a sleeve of wood to slip over it, or scratching it up and painting it a color that'll compliment the wood after I stain it.