Hydroforming Sphere with a Pressure Washer

How to make perfect spheres from sheet metal, without an expensive hydraulic press or metal spinning lathe. This method can be used for spheres and other rounded shapes of all sizes, which I will continue to explore by creating bespoke pieces for products and sculptures.
More projects: www.connorholland.com/
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#hydroforming #metalworking #sphere

[@ConnorHolland]

After receiving many requests to hydroform a football, here it is: kzbin.info/www/bejne/i2TNlnuPjpuqqbM Please watch and share!

[@adamschaeffer4057]

That's why the Empire was so interested in Kamino. They needed a lot of water to inflate the Death Star

[@StudleyDuderight]

Damnit...

[@myfavoritemartian1]

When tuning 2 stroke race bikes, we used to make custom expansion chambers the same way, But we used a "Port-o-power" foot pump and hydraulic oil. It made 10,000PSI. and did a great job. It could repair race damage too!

[@mb-3faze]

Amazing, your welding must be pretty good.... Other people use explosives - there are some great videos... kzbin.info/www/bejne/qGGul5KNotKloqs

[@devincasebeer4459]

Repair race damage?

[@myfavoritemartian1]

@@devincasebeer4459 For when an expansion chamber on a two stroke gets dented or smashed. Heat the dents then let them cool. That softens the area. Then plug one end. Hold it standing up and pour full of oil and cap the end. I used a 10,000 PSI Porto Power air foot pump to pop them back out. Expansion chambers are made for each race motor to tune it to an RPM band. You cant go out and buy one.

[@MrHeavy466]

@@myfavoritemartian1 Thus the need for such a technique. Cool.

[@beezowdoodoozoppitybopbopb9488]

​@@myfavoritemartian1 do you run into issues of redenting the area, but now it's worse because the metal was softened?

[@johnnymnemonic69]

Crazy how it doesn't violently explode like it would when filled with air

[@jackmclane1826]

It depends if it would. This one was leaky from the start. With good welds this would probably also explode as there was significant air inside.

[@charleslambert3368]

People who do stuff with compressed air systems often do a pressure test first with water or something else incompressible for that reason.

[@StuninRub]

​@@jackmclane1826No, water is not compressible like air.

[@heyhoe168]

​@@charleslambert3368 In worst case scenario volume of air matters, because air volume is equivalent to stored potential energy. However it clearly did not fail to the point of explosion. Also this system is small, I dont think it is dangerous to test it with air.

[@elricthebald870]

With air a failure would have been lethal.

[@Beschaulichkeit]

The pressure washer method was critical to a very successful project I created a year ago. I was just reminded that I first found your method quite some time ago and that planted some seeds. Thank you for sharing your work!

[@ConnorHolland]

I also found the method from watching videos, so I'm happy to help pass it on!

[@spinafire]

I first saw this from Colin Furze making stainless steel pulse jets. MacroMachines did a similar idea with just a grease gun for anyone without a welder or pressure washer interested in making steel domes. Great demo with excellent end result!

[@MikeOrkid]

I like how you left the welds on the finished product. Always awesome stuff from this channel.

[@ConnorHolland]

Thank you, I like the welds showing that it's homemade, and not perfectly smooth like a mass produced one

[@Cacowninja]

0:00 When you first start 3d modeling. 0:32 When you get really good at it.

[@GabbaGandalf420]

Bro just spawn a sphere

[@glb5099]

Bro just press shade smooth

[@MrMacio484]

bro just subdivision surface

[@splatoon4ik]

as many people say: the balls harden

[@DanteYewToob]

You never disappoint. Always something interesting and cool to look at! Could you maybe to a video about this process? Like prep, and clean up… how you get the insides dry and avoid rust, etc for those of us interested in trying the process.. you must’ve done a ton of trial and error and learned a lot by now, it would be cool to share info and maybe come up with a few simple projects to try. I’ve actually been wanting to make a fuel tank for a dirt bike using this technique… I just haven’t wanted to try it since I’d be starting from zero. Either way, that sphere looks great… I’ve seen people botch this before and end up with a crooked mess. Damn good job!

[@ConnorHolland]

Thank you! I like the idea of doing a beginner's guide, showing all the details for those who want to try the process

[@DanteYewToob]

@@ConnorHolland It would be really helpful, especially since it’s a pretty uncommon technique and not something you see on any other maker channels. With your knowledge and video quality, it would probably be the only guide on the internet for hydroforming sheet metal at home! Edit: yep. After double checking, it’s basically just you and two really old Colin Furze videos, but NO ONE should ever learn building advice from Colin… hahaha lovely guy, brilliant man, good dad, decent plumber… awful example of safe tool handling and responsible workshop etiquette! Lol Love the guy, but I’d feel much more comfortable learning techniques from someone who hasn’t caught on fire as many times. Seriously though, you basically have a monopoly on this whole thing right now. Capitalize on it if you want to!

[@kexcz8276]

Amazing usage of knowledge- pressure in a closed space is equal in all spots, resulting in a perfect sphere . Great one!

[@loonator1995]

Thats right, but not the reason why it works. The reason it works is because the pump wants more fluid inside and a sphere has the highest volume to surface ratio of all three dimensional objects. Surface is "fixed" in this case so the volume can only increase by changing the shape. By "fixed" I mean it takes more energy to lengthen the sheets than to bend them into a sphere.

[@kapralas]

​@@loonator1995that's not right either. The reason why the pump is even pumping water into the sphere, is because it can generate a lot more pressure than the pressure in the water and air inside the sphere. If there were no welds and it was a perfect steel sphere, the pressure would eventually equalise and the pump would not be able to add more water in

[@loonator1995]

​@@kapralas You explained some stuff thats not directly related to what I said. And then you don't even point out what I got wrong and why. Thats amazing. Tell me what you think I got wrong and why. Thanks.

[@ThePainkiller9995]

​@@kapralasthat's also not how it works. there's tiny gnomes inside who push on the ball bc they don't want to drown

[@BunkerSquirrel]

crazy cool man. Almost looks like special effects when it "blows up" like a balloon. Much talent!

[@K_End]

I was expecting it to instantly pop into shape, it just looks like a balloon

[@Dovorans]

That would make a great ornament for the a town square's Christmas tree!

[@incorrigiblycuriousD61]

Fascinating, beautiful and oddly satisfying. More!

[@edwardcarlton]

So amazing that this works.

[@orangequant]

Fascinating- thank you! So it had tiny leaks rather than explode, interesting. How about inserting a balloon inside the structure and sealing balloon's open end to pressure washer nozzle?

[@der_pinguin44]

Wait, hold on. You mean to tell me you're gonna post a video on the Internet without giving us 14 minutes of an unnecessary tirade about the difficulties of finding the right material, that nobody understands the complexity of hydroforming, and annoying us to no end? Two thumbs way up.

[@nigel900]

Outstanding! 👍🏻

[@CloudandZack1st]

So satisfying.

[@500features]

Got here from colin furze. I never knew this could be done so easily. Mindblown.

[@shaddoty]

People have been doing this for ages, still blows my mind

[@AndreasWeiller]

By far the coolest thing I've seen today. Thank you!

[@MrRazzio]

this was so satisfying to watch. thanks!

[@Jianju69]

I love this so much that my mind is racing for uses of spherical steel tanks...

[@fun_ghoul]

You can make all sorts of complex shapes with hydroforming, not just spheres. Go see what 2-stroke dirt bike kids do with their exhausts...

[@Aviannauts]

its like a real life subdivision surface modifier!!

[@humanspirit3432]

Really cool method : D Well done : D

[@timtim4726]

Surprisingly satisfying 🙂

[@That1Knife]

I've seen this done before (Colin Furze) but this is always cool to watch, and made a better sphere which was very cool.

[@MartinMaat]

I am impressed/surprised to see how seemingly perfect it ends up. The steel must be quite soft. But still I would expect it to spring back a bit once the pressure is removed yet it rolls like a perfect ball.

[@JontheRippa]

Good work, respect ❤️‍🔥

[@californigirl]

That's just fun to watch!

[@screaminlordbyron7767]

Ive seen compressed air used to get a dent out of a motorbike gas tank but this is wild !

[@a-a-rondavis9438]

The balls harden

[@user-ld2xi9mn2e]

That's ballin!!

[@mybackhurts7020]

Anybody else get the Star Wars feel from it

[@tatertotsjackson9984]

I legit came here because I want to fabricate a steel BB-8, then I see the Star Wars stuff in the back 👌👌👌

[@rickyspanish3714]

Nope

[@James-mq8ff]

​@tatertotsjackson9984 I'm doing the same thing hahah!

[@dougsholly9323]

The more impressive part of this was the welding of the pieces. The high pressure turning it into a ball was not unexpected at all.

[@NijeBitno72]

This has to be the most satisfying video i've seen in a long time

[@bx4hy7kr7p]

初めて見ました。驚きと面白さ満点。

[@josephwheeler1]

It's not really surprising that some of the weld joints failed considering in order to hydroform you have to push the metal past its failure point. I know the welds are supposed to be stronger but obviously there were some imperfections.

[@mikelong9638]

I also noticed that, but I end result was a nice sphere, not a pressure vessel.

[@markmitzlaff8672]

the welds were very oxidized, meaning they didn't have good gas coverage when welded. They were grey when they should have been golden to blue at most.

[@dustin7845]

Hey Connor love the videos! There aren’t to many people playing around with hydro forming so it’s neat to see. I designed a quick method to try explosive hydro forming, and was wondering what thickness of metal you used?

[@ConnorHolland]

I use 1mm thick mild steel. Would probably be better to use thicker sheet with explosive

[@samday6621]

Amazing!

[@ThomasDoubting5]

Thats satisfying

[@Jonathan.D]

I can find only one problem with your videos. There's never enough of them! I want more! This one is really cool. You have to try to do with explosives like they do with the big ones. 👍👍👍

[@ConnorHolland]

An alternative to explosives would be injecting air, using a quick release valve from a high pressure tank. Taking the necessary safety precautions of course

[@TheRoastGlint]

@@ConnorHolland do it!

[@rkan2]

@@ConnorHolland I wanna see you make a small boat like the Aussie guy

[@einundsiebenziger5488]

There are* never enough of them.

[@dethmaul]

Does the water pressure make a relatively perfect sphere, or does the quality of the welding and assembly count toward the quality of the final product?

[@ConnorHolland]

The geometry is the most important factor, so good assembly is crucial, and the welds have to withstand movement and pressure

[@JohnFrumFromAmerica]

If your welds are not good enough you will end up with a hemisphere.

[@boatboy222]

I think to do it really good you need to purge the inside with nitrogen or something when welding to help make a better weld?

[@PeterParker-df6ce]

nicely done.

[@mr.papaveraceae3009]

That's awesome.

[@Hug0_67]

Hello, I would like to get into hydroforming and I would have liked to know how much pressure was needed and what thickness of sheet metal did you use. Thank you

[@ConnorHolland]

I use a 90 Bar pressure washer and 1mm thick mild steel sheet

[@Hug0_67]

@@ConnorHolland Thank you for your reply. Have a good day

[@grantw623]

Would you mind sharing the dimensions of the starting pieces? I'd love to try this with my students.

[@ConnorHolland]

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

[@31ECO]

@@ConnorHolland thx for sharing the dimensions, however how to determine the cylinder size in relation to the cones?

[@ConnorHolland]

@@31ECO I drew it in 2D first, as a rectangle and two trapeziums inside a circle. I judged by eye what proportions looked right, and multiplied the width of the rectangle by Pi to get the circumference of the cylinder

[@the_omg3242]

I love how even after it looked spherical you kept expanding it a bit more. lol.

[@D3Industries]

Hi, great video. What gauge material are you using for this? I would think anything around 1mm would be suitable for say a water feature. It should be easy enough to work form and be strong enough when finished product, but interested to see what you have used. Thanks!

[@ConnorHolland]

Thanks, I did use 1mm thick steel

[@D3Industries]

@@ConnorHolland, thanks. Any extra tips for hydroforming? Looks pretty straightforward I guess. Do you TIG or MIG your pieces?

[@ConnorHolland]

@@D3Industries My next video will be a full tutorial about the process, TIG is the best way to weld

[@GenuineTraumatizer]

As someone who does hydrostatic pressure testing in their line of work This terrifies me Cool as heck though

[@Porphyrios1]

Why? I've been a boilermaker for twenty years. Water doesn't compress, hence why it's used. I regularly see 2000 pounds of water pressure blowout, it's nothing. Now 2000 pounds or air, that'll turn you into a fine mist.

[@FrozenHaxor]

@@Porphyrios1 You can clearly see it was half full of air in this case, storing massive amount of energy in there.

[@Porphyrios1]

@@FrozenHaxor you can also clearly see it never being sealed to begin with and immediately blow the air out of it until it's filled with water when it expands from the pumps dp but I'm not even taking about this. I'm just saying if your living involves hydrotest that's more than likely the safest part of your day & it's strange to be concerned over this.

[@bugsy742]

⁠ you are taking his comment too seriously brother 👍 He doesn’t mean this actual instance but rather the process and the sights & sounds we are witnessing reminds him of his job and the inherent dangers therein 🤝😎

[@Porphyrios1]

@@bugsy742 Being scared of a hydrotest in the types of jobs that perform them is equivalent to a soldier who's under active enemy fire & artillery having a panic attack about being stung by a bee. You've done a dozen things that day exponentially more dangerous than a hydrotest. It's just strange is all.

[@therealmattseal]

I'm actually amazed. You learn something new everyday! This was my 6th today, but shh, no one needs to know...

[@dinamiteurdinamiteur2324]

Work surprisingly well

[@rexnemo]

This sphere is a member of the onion family . I can recognise a leek when I see one .😁I'll show myself out .

[@Derek_Garnham]

There's not a dry eye in the house.

[@DH-xw6jp]

[Golf clap]

[@vaill.7807]

The balls harden.

[@avus1.8t48]

toooop skills mate thanks!!

[@justinthymes5680]

wow thats cool!

[@WiIdbiII]

I met my wife 30 years ago. And this is what happened to her.

[@joepearce3033]

Excellent

[@sapinit4322]

Simply WOW

[@thomasmica2856]

Это волшебно !

[@bugsy742]

Amazing

[@robinradema1]

Very cool.

[@mlb6d9]

That's pretty danged cool!

[@h-leath6339]

Ball Report 2023: Still hardening.

[@howtoguro]

I remember seeing this first on mythbusters and it was wild then, great job!

[@BluRibTac]

Now that is cool!

[@seabassmastermatt80]

NGL that's pretty cool!! 😎

[@EdKidgell]

Cool!

[@wovada]

It's interesting that you did it. And if a balloon with a diameter of 2 m is also inflated?

[@GWAYGWAY1]

There is air in the sphere and that is compressed by the water which is why It sprays after the pump stops,. Best fill it with water and drain the air again then do it. Glad you welding leaks like mine did.

[@u1zha]

Hoses also are elastic, spraying can continue for other reasons than trapped air.

[@screwsnutsandbolts]

Very nice 👍

[@ConnorHolland]

Thank you!

[@screwsnutsandbolts]

@@ConnorHolland You're welcome !

[@theopoldthegamer4284]

Wondering when I'll see someone joke about "The balls harden!"

[@user-yl5rl7tg2j]

beyond cool

[@seardrax527]

that title wasn't lying, that pressure washer can really hydroform

[@stuffthings1417]

The end result shown on that hex table was nice.

[@jensknudsen4222]

Just. Wow.

[@christiangrey3645]

Dude goes from PS1 to PS5 in 30 seconds.

[@saveurmind]

As a tig welder, I'll definitely have to give it a try on Monday. :D

[@garyr7027]

I'm more impressed with the pump that does this than I am about the results.

[@BernhardSchlegel]

Thanks!

[@ConnorHolland]

Thank you, I'm pleased you like the videos!

[@stuartclarke9241]

Connor this is brilliant mate what weld method did you use mig or tig? also what tool did you use to form it?

[@ConnorHolland]

Thank you, I used TIG, and all the details are in my 'DIY Hydroforming Tutorial' video: kzbin.info/www/bejne/oX7daX2jebOJr9k

[@stuartclarke9241]

@@ConnorHolland Thanks mate I'll check it out 👍

[@sonofadeadmeme]

the two categories of comments here: 1. "great craftsmanship, its very interesting how it withstood the water pressure and created such a polished result" 2. "the balls harden"

[@jeffhotes2673]

When you go from low resolution to max resolution.

[@yoyofargo]

I've been on the internet for too long to not have the "the balls harden" meme playing in my head this whole video.

[@goaheadmakeourdayscooterpe9644]

I tried that with a custom field roller I made from 1/2" wall 2'dia. gas line leaving it sit out one winter full of water,but it blew the ends out snapping the trailer axles and twisted the frame. Amazing the power of freezing water.😂

[@6663000]

awesome

[@sicks6six]

when you think you're a good welder and 0:38 happens

[@darkblades1201]

With the welds been left on, it looks like the treasure planet map

[@rickjames5998]

i fkin love that movie and that british cat woman

[@ShredCo]

The cube's graphics get much better towards the end of the video.

[@JohnRR]

Very cool, thank you for sharing. How much water pressure would a 600 mm diameter, 6 mm pre-sphere require to get round? Or maybe 4 mm. I want to make a spherical stove/bbq that resembles a sea mine.

[@ConnorHolland]

I have not yet reached the maximum pressure from my small 90 bar pressure washer, but I have only been using 1mm sheet. If you use a more powerful washer, such as a petrol powered one, then I think forming the 4mm should work fine

[@JohnRR]

@@ConnorHolland Hi thanks for responding. I guess i should just find out by trial and error. Thanks again!

[@Vikvey]

​@@ConnorHollandGreat! how to calculate the workpiece for the sphere? Is there a formula or calculation principles? or program? can i get your drawing? Thank you!

[@ConnorHolland]

@@Vikvey 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. I should do a tutorial on this soon

[@kobayashimaru8114]

Was holding my breath waiting for the POP like those spherical storage tanks

[@CutMeSomeSlackTheVII]

SPHERICAL

[@MrJjhemi]

Cool

[@psychoairsoft7146]

Paint it like a soccer ball and leave it in a soccer field somewhere lol

[@GryCkt]

This hydroforming method is also used for some bicycle frames.

[@ivanivanovic5857]

Those are some strong welds

[@LuisMiguelGarciaTorres]

some of the larger more industrial ones are formed by setting off an explosive charge on the inside. think you could try that?

[@fun_ghoul]

The FBI won't like that video...

[@LuisMiguelGarciaTorres]

@@fun_ghoul easy, just wear a BLM shirt and dye your hair a color of the rainbow

[@tolkienfan1972]

Nice