DIY Hydroforming Tutorial

[@mjremy2605]

Wow, that is fascinating. Who would think a pressure washer could accomplish all that! You are amazing. This creates so many artistic and functional ideas. I would not be inflating something next to glass doors though and I would stand behind a wooden door in case of an explosion from weld failure. You never know till it happens.

[@timferguson1526]

Wow something I never thought of! I like how you calmly do the impossible!

[@randalrobinson3424]

Great idea. You mentioned minimizing trapped air, but it would be good to emphasize how this reduces the chance of a dangerous explosive weld failure

[@ConnorHolland]

Yes, see my latest video for a demonstration of what happens when there's trapped air

[@drd1924]

Did you ever play with those little rockets as a kid, where you filled the rocket half with water, then pumped it up with something like a bicycle pump?

[@aleks_zink_works]

You are such an artist Connor. There`s something very satisfying in decorative hydroforming. Thank you for your videos and persistence. I always wonder what you gonna come up with next. :) Bless you.

[@ConnorHolland]

Thank you very much!

[@johncichon9499]

Thanks for an informative and well put together video. About 4 years ago I was quoting a similar type of job where 2 pieces of 1.5mm thick sheets were seam welded and a valve welded in on one of the edges. This was used as an expandable pillow that, in the flat, was slid into a sawn section of quarry rock. It was inflated under high pressure causing the cut to expand and separate the rock into a manageable size to handle. I'd love to see more of the shapes you have made👍

[@ConnorHolland]

Very interesting, it is impressive how much lifting/splitting force can be generated by inflating relatively thin sheet metal. I'll continue to share my experiments with new shapes on here

[@triggeredwelder]

Using the ground clamp as a clamp, I luv it

[@DanielSMatthews]

Can you draw annealed lines on the sheet metal with a blowtorch to guide crease formation in situations where the geometry allows for more than one outcome and you don't want it to be random?

[@ConnorHolland]

That could work, it may be more effective to get the lines red hot and use compressed air (under 100 psi) to inflate

[@DanielSMatthews]

@@ConnorHolland Ah yes get them started then finish with the hydro.

[@michelguerrerostudios]

THAT'S A GOOD WAY TO BUILD A GAS TANK.

[@quartfeira]

Please keep up your awesome work mate! I'm impressed how cool this technique is and how many things you can virtually do! Actually you inspired me a lot, I make furniture with wood and metal but I'm always been intrigued by stainless steel... I was just thinking these days what can I do (since I'm a novice tig welder too) and you have been the inspiration, that little spark that i needed. I thought that for the hydroforming procedure was required a much higher pressure, and apparently is easier then I thought... at least in terms of tools that are needed. I'm happy! Please, keep it up. 😊🤙🏼✌️

[@ConnorHolland]

Thanks very much, I'm pleased to hear that!

[@joshm3342]

He ACTUALLY does things, not virtually.

[@moodlemech]

Wow niiice. So now all we need is a CAD/FEA program that can predict the stretch and then produce the templates, then pump them up for a perfect part.

[@NIHILWR]

Idk why but you were in my recommendations today. Very cool video, never heard of this before.

[@AndrewJohnClive]

Me too!❤

[@1972Ray]

I worked at a place that made pressure tanks. You had to certify the welders for pressure, because it's much harder to have zero leaks under pressures much greater than a pressure washer can generate. Amazing video.

[@somaday2595]

The pressure washer I use to wash the house and vehicles is 3800 psi.

[@johnathon007]

@@somaday2595 Some pressure tanks are rated over 20k. Hydraulic systems can be crazy.

[@jpsimon206]

I was surprised by your statement suggesting those concerned about rust could use stainless. Have you tried this? I have messed around with DIY hydroforming, both pressure washer and grease gun techniques. I have never had a successful expansion in stainless, I have tried several different grades and thicknesses. I think it is because it work hardens so quickly. May I ask, what stainless have you tried? Did you find some trick to negate the work hardening?

[@ConnorHolland]

Here's me using stainless: kzbin.info/www/bejne/laO5ZX2qatJgsNU It is 0.9mm thick, grade 304, and I treat it exactly the same as mild steel, which fortunately has worked well for me

[@qnner]

05:40 you could place a small tube up the hole to speed up the draining significantly. No need for a blowtorch for draining. Not too expensive for you to try it. 👍

[@ConnorHolland]

Yes a straw also works, it helps get air back inside to let the water flow out

[@Interdiction]

I will be making some Hydroformed fuel tanks for my boat . It seems easy enough . Thanks for the informative vid

[@mjremy2605]

Now be careful. When you have unequal pressure on metal thickness and joints or by form, you can have a failure in the ocean, polluting it, leaving you with no gas and fire possibility. Fuel tanks like gas tanks have to meet stringent safety tests. Gases accumulate and create lots of pressure. I would absolutely not do that. It may void your insurance liability and could result in negligent criminal homicide charges.

[@exploringgodscountry]

My Corvette's frame was hydroformed. Super cool!

[@robertweekley5926]

Adding a Wooden Mold Frame to Expand into might be one of the ways to expand the possibilities of Shapes to squeeze into!

[@ConnorHolland]

I'll like to try mold making using steel, as wood could break due to the huge force involved

[@runcycleskixc]

Does this work with aluminum, and how does the pressure scale with the vol of the part (linear?)

[@ConnorHolland]

Yes it works with aluminium, and parts get easier to hydroform the larger they are. Because of its small volume, my hydroformed slingshot was able to take the full 90 bar of my pressure washer

[@C2welder]

Can you do it with a circular piece so you can create two shallow domes?

[@ConnorHolland]

For circles you would need to use thick steel mold, as the edges pull towards the centre, usually making a large dent. To make 2 domes I would make a sphere and cut it in half: kzbin.info/www/bejne/bHXZiHd5oseDrtU

[@christoffermartensson7978]

How did you let out the air? By filling without preassure and a not tight fitting?

[@ConnorHolland]

That's right, at 4:38 I'm pointing at the air bubbles escaping

[@laynekobain]

Very awesome tutorial, I agree the possibilities for this technique are immense. definitely going to dedicate some time to this eventually, keep it up!

[@charlesgraham9954]

i learned to Tig weld on aluminum with a thumb trigger. but i have Tig welded with a foot feed. i don't care for it. man thank you for your time making this video, i truly appreciate it, i know how long they take to film and edit. u gave me an idea how to make my own fenders and door panels for my 33 Ford Tuck. again, thank you..!

[@jiribunata5273]

Nice work! I watched your videos with enthusiasm. May I ask you what is the sheet thickness you use and what is the material specification? Is that standard DC01 sheet or some deep-drawing material ?? Last question.. I am thinking about copper or brass sheet with soldered joints instead of welded . Did you happen to try as well ? thx

[@ConnorHolland]

Thank you, I use standard 1mm mild steel sheet. Brass with brazed edges should work just as well as steel, copper and solder could work if the joints are able to cope with the movement and pressure. I haven't tried them yet, but they would look great polished up

[@dinacaldwell7522]

Well this is quite groovy I must say. Impressive creativity

[@letsmake4884]

Hi nice work I have a question How much pressure I need to forming sheetmetal size D 2000mm 4mm of thickness

[@ConnorHolland]

I'm afraid I don't know the exact pressures and haven't tried hydroforming 4mm thick sheet, but it should be possible with a powerful pressure washer

[@letsmake4884]

@@ConnorHolland thanks👍

[@letsmake4884]

Hi how are you I finished my hydr... Machine for sheet elliptical size 2.5x1.86 meter 4mm I'm happy for result 50 bar

[@DanteYewToob]

Great video! Perfect timing too, since I recently showed your videos to a friend and he wanted to try it out and I told him you’d probably release a tutorial sometime soon… haha That was a great welding tip too… I struggle with perfectly straight lines and I’m still learning, so that angle iron guide trick looks like a great way to rest your hand/wrist. I’m definitely going to try that out!

[@ConnorHolland]

Happy I could help, you can have some of the credit for being the first to ask for a tutorial

[@toroddlnning6806]

@@ConnorHolland can you use this method to round the shape of a bouthull of a 19 foot aluminim construction with lets say 4mm thick sheeting?

[@finnmcrae]

Any idea what pressure roughly stainless steel takes to hydroform completely?

[@ConnorHolland]

I don't have a gauge, but the pieces I've done have ruptured before reaching 90 Bar. I also inflate some pieces with air pressure using 100 psi or less. I use 1mm thick steel, so going thicker may need more pressure

[@chrissartain4430]

Very good video, this opened my understanding to a whole new idea of art.

[@howacarworks]

I love your presenting style and your explanations. Absolutely perfect explanation and demonstration. Subscribed!

[@ConnorHolland]

Thank you so much!

[@TheAussiePirate]

Thank you, that was a very good run through.

[@SerafinSoriano-c6q]

What pressure do I need to mold 1.2mm thick stainless steel? Does it vary depending on the way you want to achieve it? My intention is to make a dome 53cm in diameter and 13cm high.

[@SerafinSoriano-c6q]

Maybe you can recommend a channel or video to see hydroforming machines.

[@ConnorHolland]

A small 90 bar pressure washer would still work, to make a dome you could try welding a strong ring around the edge, to help stop large buckles forming

[@ChrisLee-qo9zl]

Your videos are really enlightening. Have you ever worked with aluminum sheet? Specifically 6061-T6 about 1.5mm thickness? Or is aluminum just too brittle? I have a project wih aluminum tubing that requires a minimal amount of expansion.

[@ConnorHolland]

Thanks, a aluminium test piece I made did have brittle welds that cracked, but annealing could help with flexibility. Tube may be difficult to inflate as it already has a circular cross section, but may be possible with strong welds and enough pressure. I know its common to form tube in industry with complex molds and high pressure.

[@ChrisLee-qo9zl]

Thanks for your input. I'll do a test piece up.

[@herzogsbuick]

this is amazing! i've done some fab work and love Ron Covell, for instance, but i've just never seen anything like this ever. wow. subscribed.

[@perspectivex]

Do you need to use gas (e.g. Argon) while TIG welding the sheets together without filler? Or also no gas is ok?

[@ConnorHolland]

Shielding gas is always needed with TIG to prevent oxygen causing porosity in the weld, among other reasons

[@Leonelvasquezaraujo]

Saludos amigo que material usas y cuál es el calibre adecuado muchas gracias

[@sicks6six]

noticed the motorcycle helmets behind you, hydroforming exhaust systems for bikes, moto-x & trials is a very lucrative business to be in, the plans for exhaust systems are free PDF online if you search for them, £1000 isn't a lot for an exhaust nowadays, worth thinking about if you wondering where this hobby could go in the future, good video and good work, excellent welding skills for self-taught using cheap equipment,

[@rZERO_game]

If you use hydrolic pressure generator and create pressure with air instead of water .what will be result?

[@ConnorHolland]

You can still inflate metal with air (I call it Aeroforming), it is just more dangerous with potentially explosive pressure releases, I only use a limited pressure under 100psi

[@gnemois]

Thank you very much! Did you use galvanised sheet metal for the project? Cheers from Indonesia

[@ConnorHolland]

I used mild steel, galvanised sheet is not good for welding. You could always get the piece galvanised afterwards

[@gnemois]

@@ConnorHolland Thank you for your reply! Is it possible to use 1,2 mm? Or is it going to be too thick?

[@ConnorHolland]

​@@gnemois Yes, a small pressure washer can do up to 2mm or possibly more, and you can go as thick as you want with enough pressure

[@gnemois]

@@ConnorHolland many thanks!

[@OMGWTFLOLSMH]

Cool. The first time I heard about hydroforming metal was when the C5 Corvette debuted. Its frame rails were hydroformed and I always wondered how the process worked.

[@kennethjanczak4900]

Nice job Thanks for taking the time to make the video and share it.

[@ConnorHolland]

You're welcome

[@wolframschweier3307]

Fascinating process. I just found a new use for my PW. Excellent tutorial.

[@maurilgboukrou9130]

Wow this is pure art.

[@BetterlookingthanuMr]

How come you don’t need a separate valve to allow the air to go? A lot of research I have done say that it’s dangerous.

[@ConnorHolland]

I loosen the screw fitting connecting the hose to the pressure washer to let the small amount of air inside escape. Larger pieces are filled completely with water, to remove the air before adding more pressure.

[@dodge7560]

Thank you for doing this tutorial,,subscribed.

[@davelowe1977]

Good demo!

[@motosill_garage]

Very useful tutorial video! Thanks. I need to try it in my projects too...

[@miloszlalek4754]

Can it be made in aluminium?

[@ConnorHolland]

It should be possible with enough experience welding aluminium. If I need a mirror finish I use stainless steel, as its stronger and welds better than aluminium

[@miloszlalek4754]

Thank you very much for your answer. Next zquestion. If i will make a ball 100cm diameter, what pcs i should weld. How do you slice it?

[@ConnorHolland]

See my video on Hydroforming a sphere, here are the dimensions of that ball: (I used this to make cone templates: www.blocklayer.com/cone-patterns.aspx , (Top Width 80mm, Base width 187mm, Height 57mm) The 2 discs are 80mm in diameter, and the cylinder is H 66.7mm x W 587.5mm) To get a larger ball, you can use maths to scale up the dimensions.

[@endurojimmy3109]

What a fantastic video. Thanks for making this.

[@IS-uh5yj]

Great VIDEO!! SEE YOU IN THE FUTURE

[@mark6302]

thats some fine metalwork

[@WarwickMalone]

We did a dome 3600 diameter 5mm steel, when the weld failed at about 250 PSI a jet of water blew out the wall of a nearby portacom office, smashed the windows and flipped the furniture inside upside down. There was no air, this was a result of the small amount of spring in the steel. If a person had been standing in front of it I think it would be worse than getting hit with a sledge hammer.

[@HK-uq9by]

Can you use a hydraulic pump with oil?

[@ConnorHolland]

Yes you could

[@717Fang]

Super brilliant idea.

[@freeman7788]

Try soldering steel with silver based solder faster to seal and recovery and low cost...

[@marcosrezende4234]

Amazing.... what is the thickness (mm) of the steel sheet ? Do you share or sell the sphere sheet template ?

[@ConnorHolland]

I normally use 1mm thick steel, here's how to make a sphere: Take the diameter you want and multiply by Pi to get the circumference, divide this by 8 to draw an octagon. You can then use this drawing to find the dimensions of the two cones and cylinder that make up the sphere. Cone templates: www.blocklayer.com/cone-patterns.aspx

[@marcosrezende4234]

@@ConnorHolland Thank you very much for your quick reply, I'm a brazilian sculptor learning how to use stainless steel... Peace and Love !

[@marcosrezende4234]

@@ConnorHolland I used blender to create templates and measure them. than you again.

[@ConnorHolland]

@@marcosrezende4234 In Blender you can also simulate the inflation by using Cloth - Pressure in the Physics tab

[@marcosrezende4234]

@@ConnorHolland hi again... I had my first success after two failures using stainless steel (too hard) For the 1mm thickness, I had to use mild steel as you advised in another conversation we had. . Have you tried it with stainless steel?

[@j.g.9524]

Awesome work:) Your TIG weld looks great! Would you like to share your settings for your welding machine? Especially the plus frequency and range is something I unfortunately never worked with:( Greetings from Germany and thanks a lot.

[@ConnorHolland]

Thank you, my typical weld settings can be seen at 1:55 I'm not sure of the exact numbers as the machine's display doesn't show them. I found my preferred settings by welding lots of scraps and comparing, then putting pencil marks next to the dials.

[@elitearbor]

Lovely! You really are bringing this technique to "the common man" so to speak. It's dangerous, yes, but all metalworking is.

[@johnnydennett4248]

It’s hardly dangerous when you use water. That’s why pressure testing of vessels is done with liquids that cannot compress. If you pumped it up with air that is compressible,then it would be dangerous. Generally what happens is you get a tiny leak on the weld seam and you can no longer build pressure . It ends with a whimper ,no bang…

[@CableWrestler]

Colin Furze already done this

[@kalleklp7291]

Collin Furze did this some years ago when he made a jet. Your TIG welding looks quite good. One can also use MIG for that but turn down the wire to an absolute minimum. Everything else would just be a waste of wire and make the result look bad.

[@ConnorHolland]

Nothing beats TIG in my opinion, except maybe robots and lasers, but I cant afford those yet

[@manxman8008]

very good idea and demo

[@joelaroche7667]

Would have been nice to also talk about the plug you insert to test the piece.

[@dennyjmitchell]

how do you make a sphere? do you have 3 pieces of metal?

[@ConnorHolland]

It's made from 2 discs, 2 cones and a cylinder. On paper they form an octagon with 8 equal sides

[@cortena1123]

Do you think I will be able to make 3 meters ball with the same equipment?

[@ConnorHolland]

The basic principles will be the same, you will need either a powerful pressure washer or a hydraulic pump. Also the weight and volume of water needs to be accounted for, and set up on soft ground so you can dig a shallow hole for it to sit in

[@miguelr1490]

Interesting, liked to see how you made the round balls 🤔

[@alineharam]

You taught me something. Thanks.

[@brettmoore3194]

When i saw that before you cut the tube off i thought that could be a mini boiler tank,. Have you tried making a lasgana style. Like to sealed tanks right beside each other. It could be a apparatus for electrochemical expirements. Oh jolly

[@davidgonzalezcordero3688]

Muy buen tutorial maestro 👍

[@babbapappa1]

Hey there, great video ❤, question can you determine the shape you create by scribing a pattern onto the flat sheet?

[@ConnorHolland]

The finished shape depends most on the shape of the outer edges. Welding, clamping or using a steel mold can affect how a shape inflates, if they are strong enough to resist the large force acting on them.

[@norfolkflyingboyz2404]

Beautiful ingenuity.😎very cool

[@Alan_Hans__]

Very nice. I wonder if the wire fed laser welders would do any sort of a reasonable job at welding for hydroforming.

[@ConnorHolland]

I think they would work well, as the sheet metal I use is so thin (

[@psjasker]

Talented young man

[@Vlow52]

Great idea! You should try welding some Platonic solids and try to inflate them to see how spherical it gets

[@metlgandalf]

Is this also possible with 3mm v4a Stainlesssteel?

[@ConnorHolland]

Yes I think it is possible, a more powerful pressure washer (>90 bar) would help

[@metlgandalf]

@@ConnorHolland thanks for the Information. Then my 180bar PW will do

[@ArcOfTheCovenant]

Test your welds under water and look for bubbles or use soapy water in a spray bottle it will also produce bubbles if leaks are present

[@ConnorHolland]

Good idea, it's frustrating having to stop hydroforming because you missed a tiny hole in the weld

[@JonMurray]

Brilliant video mate. New subscriber ✌🏻

[@X3msnake]

Awsome video Master. Thanks for sharing What are the safety concerns with hydroforming that one should be aware besides using eye protection gear?

[@ConnorHolland]

It's basically the same precautions you would take when cleaning using a pressure washer (avoid touching the jet), and make sure to expel any air trapped inside the workpiece, which can cause more energetic ruptures

[@nothanks7285]

Very cool video, what a nice skill to have. I'd love to try & make fenders and/or gas tanks for motorcycles with this method. Someday!

[@GWAYGWAY1]

I built an expansion chamber like this to save doing loads of pie cuts . It leaked like a sprinkler showing my faulty welds in the seams.

[@fibranijevidra]

I thought you were going to use some kind of mold and specialised forming compressor. Not very precise, but still very usefull. BTW. that edge welding was very satisfiying to watch.

[@chainda066]

Oh! So amazing How much psi?

[@ConnorHolland]

The 90 Bar pressure washer is around 1305 psi

[@chainda066]

@@ConnorHolland Thank you very much, I will try to do it

[@juliewren2443]

Great video well done!xx

[@johndoe1765]

And thank you great work it's very interesting.

[@deanharris7149]

Awesome vid! More would be appreciated.

[@LeLa-Random]

How thick was your sheet?

[@ConnorHolland]

1mm mild steel

[@alan_wood]

Very useful, thank you.

[@fsj197811]

Cool stuff, thanks for sharing.

[@balloney2175]

I wish you demonstrated more.

[@DrakeVideos]

haha what a great video, It's interesting to know how easy this can be and your explanations throughout were clear and to the point it was awesome you just let it break as i really wanted to see that when you mentioned it, not as powerful as expected. Loved the little warp out!

[@ConnorHolland]

Thank you!

[@firstdayonline]

Excellent! Thank you!

[@datsil]

Watt steel?

[@ConnorHolland]

1mm mild steel

[@nob5000]

Great awesome good job i always wanted to do that

[@mikex691]

Talent!!!!

[@PizzaCat1732]

Nice welding!

[@DiedrawingChinaFactory]

Great idea

[@2150dalek]

Incredible.

[@patjohn775]

Have you tried stainless?

[@ConnorHolland]

There are a few stainless projects on my channel, here's the most recent: kzbin.info/www/bejne/jnyWhpusiZ6Ye7c

[@nandingpanelo]

Thanks

[@henmich]

Not going to lie... This was amazing.... I'm shocked a pressure washer was enough to do that.

[@TRechs]

Great video!!

[@marcosmacli1061]

Hola que gran trabajo, muchas Gracias por compartir, saludos

[@brighambaker3381]

Awesome video! Thank you for the instruction!