Homemade Corrugated Iron Roller (well, nearly!)

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for a while now I've been thinking of

making little animal houses for sale

using a pallet for a base with a curved

corrugated iron roof and the back in the

front I thought people might like them

maybe for dog houses or hen houses or

play houses that sort of thing that's

the plan anyway the main challenge of

course is the corrugated iron roof it

would need to be rolled over very


to fit a palate after choking at the

price of new corrugated iron rollers I

decided I make one myself how hard could

it be well it turned out to be much

harder than I thought

first up if you remember I made a simple

slip roller to test the principle and

the materials if a roller like this

could work then there was a good chance

I could develop the same idea of what I

really want I've since modified this

design a bit and it works even better

so that worked and I then set out to

make some special rollers ones that fit

into the corrugations in the iron sheet

well stewardship but they call it

corrugated iron toe anyway my first

attempt was to make lots of donuts

out of four millimeter steel my thinking

was that if I measure everything

carefully they should stack together in

the right shape it wasn't a bad plan

exactly once I'd figure out how to key

them to the shaft without any welding

which would have deformed the pipe but I

gave up on it anyway when I realized I'd

need about 400 of these disks the weight

and the cost would have been huge so I

went to talk to our local engineer how

much would he need to charge to turn

these rollers out of steel stock he just

laughed at me and said more than you can

afford him which was undoubtedly true

but then he told me that 50 years ago

there used to be a man in a neighboring

town who had a roller for corrugated

iron and his rollers were wooden uh-huh

wooden rollers a bat sounds doable so

that's when I made my copy lathe because

I needed these rollers to be accurate

and identical now I'm guessing a wooden

rollers would warp unless you have

really good beats wood or something

which I don't have so I invested in some

expensive Search Appliance Ted and built

up layers with lots of glue my first

attempts were all timber but I'm glad I

decided to go with a box iron core and

you'll see why in a minute


and all backward well I turn them down

to a cylinder and then I deployed a

template that I've made and I carefully

to earn the shape with a square and it




and then finish them with a round nose




and so far so good and death is a big

bet that when the problem started

I set the rollers up in a frame with

Koch wheels to connect to them the third

one was arranged so it could be lifted

up with a jack and then it would drop

out of the way at the end of the job and

the main problem is simply down to the

pressure needed to roll call a dented

iron I had completely underestimated it

I used a hydraulic jack to lift the

third roller and immediately the frame

began to twist and distort when I turn

the handle and I found that if things

are even a tiny bit out of line then the

sheet starts wondering of course and

straight into the cogs or it might roll

unevenly twists

I eventually solved all that by

triangulating everything with chains and

bottles screws and that brought it all

back into alignment and together with

another jack to even up the pressure on

the third roller I could at least do the

shoot properly but a problem is it's

really hard it's actually difficult to

roll this banging to you the rollers

there's so much pressure needed


I did eventually roll a piece I have

made a corrugated iron roller then I

rolled it the more and it's okay

but I hope I can do better than this

there are kinks where I don't want kinks

and it took hours and my arms are in

pain now so I took everything apart and

I reconfigured it so the rollers were

closer together I'm guessing that's the

reason for the kinks I had to make some

more sprockets so the two bottom rollers

are the driven ones and the last sheet

of corrugated iron I had I cut it up so

so it's not to waste any more and I

rolled it very carefully and it was on

whole lot better still not perfect but

much less skin okay

I suspect I could keep improving the

finish but there's no way that this

would be cost-effective without a large

motor to do the work it's just too slow

and too exhausting so there you go

that's an insight into one of my mini

projects which isn't that successful

lots of time and effort went into this

one and it's a bit disappointing really

I think I'll do something else for a

while while I plan my next move with it

unless you have any ideas