Hello. Today I want to talk about a magnetic welding square that I recently made. I will soon have to make several gates and entrance gate, so I decided to make some magnetic squares this winter. They will save me a lot of time and effort when welding rectangular structures from profile pipes.
Here's what I needed for this:
1. Old speaker from a car stereo.
2. “Magnetic” sheet metal (steel) 1 millimeter thick
3. A strip of thin aluminum.
4. Blind rivets.
As you know, speakers have fairly powerful ferrite magnets.
Using a hammer and chisel, I separated the "magnetic part" of the speaker. (It is secured with four rivets).
After this, all that remains is to remove the magnet. It is located between two steel plates and secured with glue. It was necessary to dip it in acetone or solvent 646 for a while... But I just took a knife, which I don’t mind, inserted it between the plate and the magnet, and separated the plates with light blows of a hammer.
Previously, I was able to do it “cleanly”, but this time the ferrite magnet chipped a little... Oh well... I’ll polish it on a diamond cup.
Next I started making the plates. I cut them out of an old window sill. (I’m surprised myself, but it was made of “black” non-galvanized iron, 1 mm thick!). The metal was very magnetic, which was what I needed in the first place.
Using a mechanic's square, attaching it and the resulting magnet to the workpiece, I determined the dimensions of my future product, drew it and cut it out with a grinder:
Next I marked and cut out the corners. Corners need to be cut for several reasons:
Firstly, when cutting a profile pipe (and especially, with a thick circle on it), burrs remain on the edge. During welding, they will easily melt and will not interfere. But the square will rest against them. (But even half a millimeter will greatly change the angle in this case). Therefore, after the pipes are cut to size, you will have to clean off these burrs, and waste time doing this.
Secondly, if there is not a large gap in the corner, you can accidentally weld the square itself to the workpiece!!!
So I cut them like this:
I did not mark the second plate. I simply attached the first one to it (already with cutouts) and, according to this template, marked it and cut it out too: 
Next I did some fine tuning. After all, it is not possible to cut very accurately with a grinder, and precision is needed down to fractions of a millimeter. Therefore, I had to finish it manually. I took a piece of a wide profile pipe, spread a strip of sandpaper on it, and manually, grinded down the sides of my metal triangles on it, periodically putting them into fitter's square and checking against the light
After that, folding the blanks evenly and squeezing them in a vice, I drilled holes in them for the rivets. (I forgot to photograph this process). And after that, just in case, I tightened them through the holes with M5 screws and once again “finished” them on sandpaper, this time two together.
Next, I want to draw attention to a common mistake when making homemade squares. Many DIYers make them "open". That is, they don’t cover the end with anything! It is unacceptable. Because when working with metal, a lot of sawdust, frozen splashes of scale, small scraps and other magnetic debris appear. Since all this debris is very light, it sticks abundantly to the magnet. Here, for example, is a photo of a weak (!!!) magnet, which I deliberately “crawled” around the workbench after I had cut out and finished my workpieces:
Do you see how much he collected?!!! The magnet itself is not even visible behind the garbage!!! This is how a magnetic square will collect garbage. And even stronger, because its magnetic properties are more powerful!!!
That is why its shape should be such that it can be easily cleaned!!! That is, its ends should be smooth planes. I made them from a thin aluminum plate. Some kind of edging from an old refrigerator shelf came under my hand.
From it I cut a strip with a width equal to the thickness of the magnet:
And from it I bent a frame around the perimeter of the plates. It will be inserted between them, and tightly clamped with rivets. The ends of the square will be tightly closed, magnetic dirt will not get inside, and it will be easy to remove it from the surface of the plates.
By the way, please note: I had to trim the magnet a little at the bottom. This is my mistake - when estimating the dimensions of the plates, I did not take into account the thickness of the aluminum plate, and then the magnet did not fit into it....
So, let me focus on one more point. A ferrite magnet can be cut quite easily with a grinder. But, unlike cutting metal, use abrasive wheel don't even try!!! It will slip and you will simply overheat the magnet. (By the way, if anyone doesn’t know, permanent magnets lose their properties due to overheating.). You need to cut with a diamond wheel. A diamond wheel for wet cutting, popularly called a “tile” wheel, is best suited. It has a continuous cutting surface and does not chip away at the cutting area:
And when cutting, the magnet must be cooled with water.
Next, I want to explain why I made the ends out of aluminum, and at the same time draw attention to another common mistake. As you know, any magnet has two poles, conventionally called “north” and “south”. Both poles are equally well attracted to the metal. Magnets of this shape have poles on planes. That is, when we apply metal plates to the planes, then these plates are the poles of the magnet. And it is with them that our square will “stick”, and not at all with the plane between them.
But, most importantly, the poles of the magnet cannot be “short-circuited” with magnetic material! This reduces its properties, and, in addition, contributes to the fact that the magnet, albeit slowly, demagnetizes! And another mistake is that many people connect the plates with steel (!!!) screws. This, of course, is already a trifle, but if there is a possibility, then it is better to exclude it. And this is how I did it...
I decided to connect the plates with blind rivets.
Welding equipment, except the machine itself and protective equipment, has a more extensive list. Most often, a variety of clamps and holders are required to secure workpieces. The presence of such additional equipment is especially important when you need to weld workpieces at different angles.
In this article we will look at what welding magnets are used in the work process and how to make some of them yourself.
Why are magnetic accessories used in welding work Oh? The technology of joining parts by welding may require the welder, for example, to place different workpieces at angles from 30 to 90 degrees or to precisely orient the edges in the same plane. Such magnets are especially useful for welding metal structures from profile pipes. Excellent quality can only be achieved by using various types of corners and holders.
Most often in welding practice the following devices will be required:
- Magnetic corners (permanent and switchable).
- Fastening devices (for fixing in one position).
- Clamps (used to clamp parts).
- Spacers (to create gaps).
Magnetic corners
The main advantage of such a device is that it allows you to reduce the time required to prepare parts for welding. Magnetic welding angle allows you to:
- Reduce the labor intensity of the process. There is no need to spend a lot of time fiddling around with securing the parts.
- The ability to fix parts of the product at almost any angle.
- The compactness of the devices simplifies working with them.
- Automate the welding process. Switchable magnets allow you to quickly connect and disconnect fasteners.
The most basic products have simple welded joints, but more often they have complex configurations and seam shapes. And no one can deny accuracy in such work. Therefore, magnetic devices with different functionality are often used: fixed and adjustable angles, or permanent and switchable magnetic systems.
The design of permanent magnetic corners is simple. These are two metal plates with a magnet located between them. The most common form is in the form of a house with gable roof, cut ridge and round hole in the middle. There are also others for cooking in all three spatial coordinates, or more simply - tetrahedrons or polyhedra, as well as cylinders.
By placing such a magnetic square for welding between parts in the desired position, they quickly secure parts of the product.
Switchable magnets
The magnetic holder for welding can be either permanent or switchable. They allow you to secure parts by inclusion.
Their advantage is that the switchable magnet for welding can be removed with one turn of the switch, after fixing the parts with welding points. This also makes it easier to clean the magnet from chips and small scraps (unlike a permanent magnet).
Also, all magnetic angles can be standard or universal. If the standard ones have precisely fixed angles, then the universal ones will allow you to weld two parts at an angle, for example, 32 degrees.
Clamps
This device is designed to pull two parts together and temporarily fix them.
The most common form is in the form of the letter “p” turned on its side. One side serves as a permanent retainer, and the other has a threaded screw clamp.
The size of parts that can be fixed with clamps is limited by their parameters.
Such clamping devices will be useful not only for welding, but also for other types of plumbing work.
The use is simple - the parts are placed in a clamp and tightened with a screw.
Spacers
To create gaps between the parts of the product being welded, you can make a simple spacer from a piece of pipe or fittings. But to reduce preparation time, you can use factory-made products.
The operating principle of such devices, like clamps, is based on a screw thread. Only functioning, on the contrary, to unclench.
How to make a magnetic square
Prices for magnetic welding jigs can range from $20 per simple devices, universal ones will cost more. And the most expensive ones are switchable ones. But you can make them yourself.
A permanent magnetic square can be made as follows: 
- From a suitable sheet of steel you need to cut plates, for example, triangular in shape. The main thing is to correctly measure and mark the corners of the triangle. All ends must be thoroughly cleaned with a file.
- The magnet can be used from any unusable audio speakers.
Accordingly, metal plates are cut to fit the size of the existing magnet.
- Afterwards the entire structure is assembled into one whole. The magnet is located between the plates. For assembly, three holes are drilled for the clamping bolts.
- To prevent the magnet inside the device from becoming contaminated with shavings and scraps, you can make end caps. Or simply periodically clean the surface by disassembling the device.
Form homemade holder can be varied, the main thing is to accurately maintain all angles. This method ensures reliable fastening of the parts to be welded.
In any case, a welding magnet or screw clamps are useful in a welder’s arsenal. Even with a helper who will hold the parts being welded, it is impossible to achieve precise angles and required parameters.
Magnetic holders will securely fix parts, and their installation and dismantling is simple and takes a minimum of working time.
Switchable magnets are very versatile in use; their mechanism allows you to control and adjust the displacement of parts.
If you have experience using magnetic holders and other devices, share it in the comments section of this article. How effective will welding magnets be in a home workshop, and what devices are best to purchase. Also important is your experience in making such mounts with your own hands, how to make them and how difficult it is to make universal and switchable magnetic devices.
When carrying out welding work, moments arise when it is necessary to simultaneously grip a part and hold it at a certain angle. This work requires two people or special tool. The most commonly used is a clamp. With its help, the part is fixed in the desired position. However, the clamp has a lot of disadvantages. Therefore, you need a special magnetic holder that will help you do this work quickly and without unnecessary hassle.
Advantages of a magnetic corner for welding
- Capable of holding both metal parts, freeing your hands to do the main work.
- It does not block access to the connection point, which makes it better than a clamp.
- Allows you to create several angle options.
- Easy to use.
- Does not require large production costs.
Magnetic corner manufacturing process
First, we need a magnetic disk with a diameter of ~15 cm and an internal diameter of ~5 cm. We also need to have squares of sheet metal 3 mm thick, with a side of 20 cm. It is very important that the sides of the square are perfectly even. It is advisable that the thickness of the magnet does not exceed the material most used in the work. The best option is 1-1.5 cm.
Place the magnet in the center of the square and trace it with a marker to create a marking. Next, we apply cutting lines to the metal that need to be made to create the pattern.
We clamp the workpiece in a vice, and use a turbine to cut off the excess elements.
We apply the resulting part to the second square to outline its contours. Next, we also remove the excess from it with a turbine.
We connect the two resulting blanks together and secure them by welding. Now we can perform one operation on two parts at once.
Next we need two threaded couplings. We install a magnet on the workpiece, applying it to the previously designated location. Then we distribute the couplings along its perimeter, at the same distance from each other. We mark their position with a marker.
We remove the couplings. We mark holes in the center of the location of the couplings. Next, using a drill corresponding to the diameter of the hole in the coupling, we make holes in our workpiece. It is through them that the bolts for fixation will be installed.
After this, we weld a piece of pipe to the workpiece, the diameter of the internal hole of the magnet. We fix it exactly in this place. As a result, we got a part that can be clamped in a lathe chuck.
Using a drill and cutter on a machine, we create a hole equal to the inner diameter of the magnetic ring.
We remove the welded pipe and clean our part. In this case, it is very important to obtain perfectly smooth edges while maintaining compliance with the corners. Therefore, you will have to work not only grinder, but also with a file. We make something unique measuring tool, which means the accuracy of the work must be at its best.
At the next stage we will need couplings and bolts for them.
The workpieces are separated and cleaned. Next, install a magnet and couplings on one of them.
Hello to all DIY lovers!
Today I want to show you one of the options for making a simple magnetic corner (holder) for welding work. The idea is certainly not new, there are many modifications of this homemade product, but in terms of functionality they are practically no different, and you can get quite a lot of benefits from this thing, considering that when welding, you often have to work alone. Actually, this prompted me to make this holder. I will describe where it can be applied at the end of the article.
Necessary materials
To make a magnetic corner you will need:Two furniture corners
- three extended nuts
- six bolts
- half a magnet (it’s better to use neodymium, of course)
Manufacturing a welding angle
First of all, we shorten the bolts so that they can fit into the enlarged nut (select the sizes individually). I cut off the bolts with a regular grinder.
Next, I sanded the magnet a little to round off the sharp edges a little and so that it would fit in the corner between the nuts.
Then I slightly drilled holes in the corner for the bolts, and also drilled additional ones in the middle of the corner in order to secure it with three nuts in the future.
Now we need to put everything together.
To make the instrument look beautiful and stand out from other instruments, I painted it bright blue.
It all turned out quite beautiful!
Using the Welding Holder
Now the actual use of the magnetic corner in practice:Using this homemade product, you can easily and simply weld parts at an angle of 90 degrees alone, without holding the workpiece.
For example, below is the photo. On the first one, a piece of reinforcement was welded simply by hand:
As you can see, the workpiece was beveled and a right angle did not work out.
On next photo the same piece of reinforcement, but using a homemade magnetic holder:
As you can see, the result turned out much better!
In addition to this option, you can also use a magnetic holder when welding parts from the side or even from below, and you also don’t have to hold the workpiece. 
Of course, this holder is not suitable for any work where large and heavy workpieces are used, but for small household work it simply cannot be replaced. And if you need to secure something large, then you can simply make a larger holder with a neodymium magnet, which has a much higher attractive force. It all depends on your needs.
Welding is fast and reliable way creating permanent connections metal parts. The process itself does not last long; it often takes a lot of time to correctly position the workpieces relative to each other. They must be fixed accurately and securely so that there is no displacement during the welding process. Many devices have been developed for this. Magnetic fasteners - angles and holders are very quick to install and remove and save the welder a lot of time.
Types of fasteners and their purpose
In order for the weld to be strong and reliable, the workpieces to be welded must be fixed. For this there are many various types equipment, universal and specialized. These include:
- switchable magnets for welding;
- screw clamps;
- screw spacers;
- magnetic corners.
Switchable magnets
In this type of equipment, it is possible to control the intensity of the magnetic field, turning it on and off. This effect is achieved by rotating one magnet inside the housing relative to the other so that they magnetic fields either mutually reinforce or neutralize each other, and the field does not pass beyond the body. Switchable magnets are placed and removed from workpieces with one finger movement. Such devices are especially convenient when it is necessary to correct the position of workpieces. Another advantage is that after turning off such a holder, all sawdust, trimmings, shavings and other small metal waste fall off it, making cleaning easier
Clamps
The equipment is designed to reliably press the workpieces against each other. Its outer part, made in the shape of a right (or other) angle with a cut out top, is the fixing part, and the inner part, equipped with a screw feed device, is a clamping device. Essentially, this is a vice with jaws bent at an angle. The parts (profile or rod) are placed in a clamp and pressed against each other with a screw.
The dimensions and shape of the parts are limited by the size of the clamp. It can be used not only for welding, but for other plumbing work.
Spacers
Spacers are used to create the required gap between the workpieces to be welded. Home craftsmen choose for this purpose cutting pipes and profiles from a waste box, but it is much more convenient to use an industrial product. The spacer is also equipped with a screw and is a “reverse clamp”. It can be adjusted to any required clearance within the screw stroke. Spacers and welding magnets are often used together.
Magnetic corners
One of the most commonly used devices is a corner. Its main advantages:
- Reduces the labor intensity of the welding process. The time for fixing workpieces is reduced several times.
- Parts can be fixed at almost any angle between them.
- The device is compact and does not interfere with welding work.
- The time for removing equipment is also reduced several times compared to clamps.
Magnetic corners are available with both fixed angles and freely variable angles. To do this, they are equipped with a hinged device with a lock.
Structurally, the equipment consists of two metal plates cut from sheet metal and secured between them permanent magnets. The most popular are universal flat corners, reminiscent of a house with a cut off roof. But there are also three-coordinate spatial clamps in the form of polyhedra or cylinders. They allow you to assemble very complex spatial structures, such as power line supports, spatial trusses, etc.
Purposes of use
The main goals pursued by the use of magnetic holders for welding work are the following:
- convenient and reliable fixation of workpieces;
- placing them in space in strict accordance with the product drawings;
- precise alignment of angles between parts;
- reducing the labor intensity of welding and improving its quality;
- replacement of obsolete screw clamps and clamps.
Magnetic welding angles have a clamping force of 5 to 60 kg and are used with sheet metal and with profile rental.
Characteristics of welding magnets
According to the degree of versatility, equipment is divided into two types:
- universal;
- corner magnets.
Universal equipment has one or more degrees of adjustment and allows you to work with workpieces of flat, cylindrical and multifaceted shapes, connecting them at arbitrary angles in several planes simultaneously. Such devices are indispensable when assembling complex spatial designs. They are given increased resistance to heat and splashes of molten metal.
For these advantages of equipment professional class comes at the expense of a high price and limited availability in regular hardware stores.
The square is much simpler in design, easier to learn and allows you to cover most of the needs of the home craftsman.
For production you will need:
- sheet metal 2-3 millimeters thick;
- round magnet (from an old speaker);
- bushings made of non-magnetic material (plastic, hard rubber, etc.);
- nuts, countersunk head screws.
The manufacturing sequence is as follows:
- Draw the outlines of the holder on the sheet. You need to be especially careful and use only a high-quality and certified square and ruler for marking. The accuracy of the assembly of your future structures will depend on the accuracy of the angles when marking.
- Using a grinder or jigsaw, cut out the parts and align their edges.
- Cut the bushings to size. It is important that they are strictly the same in height and have smooth edges.
- Pick up a piece of elastic plastic and fix the magnet along its inner hole.
- Mark the places for fastening, drill the plates (preferably together).
- Assemble the product by putting the bushings on the screws and placing them and the magnet between the plates.
The clamping force of the product depends on the accuracy of the assembly and the magnetic properties of the metal; before welding, it will have to be determined experimentally.
Magnetic holder for DIY welding
This is another design option for a magnetic corner for DIY assembly. It will require:
- metal sheet 1-3 mm;
- neodymium magnets (so-called “screw magnets”);
- dry board;
- nuts, countersunk head screws, self-tapping screws.
The manufacturing procedure is as follows:
- Mark and cut two identical blanks from the sheet, carefully monitoring the accuracy of the angles.
- Make the central part of the holder. Cut it out of the board so that it follows the contours of the metal plates, but recedes inward to the height of the magnets plus a millimeter to one and a half.
- Fasten the metal and wooden parts of the product together.
- Screw the magnets to the wooden spacer along the perimeter so that they are at the same distance from each other.
Before starting work, you need to check the geometry of the resulting equipment - its angles and dimensions.
How to make a switchable magnetic square
The cost of magnets for welding ranges from hundreds of rubles (household models made in China) to tens of thousands (switchable universal professional devices famous brands with the ability to work in many planes and arbitrarily set angles). But it is possible to make their analogue yourself:
- Cut two triangular-shaped plates from a sheet of metal (or in the shape of a house with a cut off roof). You need to carefully monitor the exact alignment of the angles.
- File the edges.
- The magnet can be used from faulty speakers or a microwave oven.
- Mark and drill through holes in the corners of the triangle and in its center.
- Using four screws and nuts and bushings equal in height to the magnet, fasten the structure so that the magnet is clamped in the center.
- To reduce contamination, plastic plugs can be placed along the end faces.
The shape of the magnet for welding may not be triangular. It is selected depending on the needs of the assembled welded structure.