Making Plastic Rod Stock - Melting HDPE Milk Jugs

In this video I melt HDPE milk jugs to get a block of plastic from which I need to make a pulley for an electric motor. Because I had no decent plywood and HDPE is easily available and great pulley material.
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SAFETY:
Don't do anything you see me do. Stay SAFE!
Here's some things I do to make this safer, but do your own research. I ain't no chemist or doctor.
- I only use HDPE, other plastics might give nastier fumes.
- I don't try to guess if something is HDPE or not, I only use the things clearly marked.
- I only use translucent HDPE, clear or colored one might have nasty aditives.
- There are two types of HDPE, the one blown like the jugs and the one molded, like caps and buckets and such.
- I only use HDPE from milk jugs, the one made in molds might have aditives to make it flow better.
- I Keep it the right temperature and work in a well ventilated room.
- I only do this rarely, constant exposure to fumes has risks.
You... should not do this!

[@NewHampshireJack]

TOTALLY AWESOME,,,the more of your videos we watch, the better it gets. In the Philippines, we often hear "out of stock" or "not available." It is a great feeling to know there is always a way when you are stuck and must make the parts to finish a needed repair.

[@vidskitkid]

An Impressive and inspiring video showing the process going from a plastic (HDPE) jug to a pulley shown in use! Very nice, thank you!

[@JohnnyWooh]

I love watching these. Very relaxing in a sense and always interesting to see things being created handmade.

[@TheSmallWorkshop]

Thank you!

[@neilfroggycrompton2466]

+The Small Workshop is that a small aluminium can u used to melt the plastic into?,(red bull size?) is it possible to chop up the plastic a bit finer so there's less air spaces?,do u think its possible to compress the plastic in the can before heating so u can get a bit extra in there?

[@neilfroggycrompton2466]

+The Small Workshop this would be ideal for making end caps for soft faced mallets or an end cap to cover the end of a metal hammer just machine a dished recess slightly under sized so it would be an interference fit,could this plastic be heated in a microwave in a non metallic container?,or would it just burn up/catch fire?

[@sorin990]

Nice video ....how can I use plastic to make myself some molds after concrete to turn concrete models ??

[@Cavemaaaan]

Great question. My mind is telling me that the microwave wouldn't work, but ya never know...

[@nateb4543]

Just got a 55 gallon hdpe barrel for $10 it weighs 9.8kg, while a milk jug weighs 60-62g. Ive been collecting virtually all hdpe containers for years and just more than doubled in 20 minutes and $10. I like the vid

[@clivebashford2900]

Excellent idea and a real life saver for some out of production rollers I've been searching for. Now I'll make them. Thanks, and you've just got another avid follower.

[@XXCoder]

Thanks for adding clear text, makes everything clear!

[@TYPE-zd3gm]

Great idea! I'll bet you could do this in a threaded (outside) metal pipe, cap the ends, tap the top, and rig a vacuum pump to it, producing a better piece still.

[@jeffbeck6501]

Amazing quality. From a 1/2 gallon jug. Great build, thanks for the video.

[@thecrazy8888]

If you want to get rid of the gaps, I think it might work to put it back in the oven with an all metal clamp on. Only problem is you may have to figure out a better seal between the can and that piece of wood. I would try to replace the can with a metal tube cut on the sides so it can be split in half, machine some groves so it lines up and turn/polish the inside to make it perfect and ease the release. Then you can machine a presser plate that fits perfectly and make hold together with metal clamps. With some soldering and few extra parts this could be turned into a great tool for repeat use. Man I need to get a lathe :)

[@1950cappie]

This video will hopefully solve problems with some of my stagnant projects, thanks for posting.

[@TheSmallWorkshop]

Happy you found something useful! Thank you too!

[@silvermaple7779]

Really great way to repurpose, reuse & recycle. Wonderful video, thanks so much for sharing!

[@TheSmallWorkshop]

Thank you too!

[@RickRose]

Nice work. I'd like to see more of that old metal lathe you showed at the end!

[@uktony1525]

Brilliant project, recycling at its very best.

[@paulstuartwilson485]

Brilliant! Absolutely brilliant! I can't wait to get busy on this project. Thank you very much!

[@TheSmallWorkshop]

Thank you too Paul!

[@DrLumpy]

Nice job. I REALLY enjoy maker videos with NO dialog or silly dance or grunge music. Thumbs on the positive Z axis!

[@rogermoore8977]

Some mallets have replaceable plastic ends on them. A hex head bolt embedded in plastic looks very similar. Threaded end of bolt projects out to screw into body of mallet.

[@DylansDIYWorkshop]

That's great to know that it doesn't shatter like other plastics would

[@colssneepe3884]

you are a star ive been looking for a pulley for a sander.i just had to sub.and the drum sanders are class

[@michaelj2439]

Thanks for the video, it was nice to see how much one jug makes.

[@GaryTruesdale]

That came out nice. Although it seems like a lot of work.

[@raiderman28]

pretty awesome how you are able to recycle plastic and make it into something.

[@michaelb.5345]

Ever try pool ques for handles. Beautiful wood in the heavy ones. Try it... Mike

[@TreasureByMeasure]

Don't know how I found you but I LIKED your video and am enjoying your channel

[@jules2c]

I have being trying to get stock for a largish gear, this could be the way and thank you for no bloody music while getting to the point.

[@Joshua79C]

For your purpose if you already have not, use a round or square 'pipe' or shaped form with smooth inside and a slightly oversize plate at one end secured with bolts or the base and a smaller one that goes inside for the top and as clamps to the top to compress as you coot it with some gap for some air to escape. Thus once formed and cooled you can remove the plates and pop the mold out if need be.

[@Cavemaaaan]

Wow!!! I stumbled across his video in research for HDPE plastic welding. Thanks for the great idea! I need to start saving my milk jugs for raw material. Great video...Thanks :)

[@hansdegroot8549]

Nice video. Thanks for sharing. You can use the shaving to melt again for a next project.

[@sedenter]

I just searched your channel an hour ago to see if you added another video and it was nothing new :). But persistence does wonders :). I'm would love to have a lathe, it seems so much fun working with it. Congratulations!

[@TheSmallWorkshop]

Thank you Eugen! You should get one! It's basically the only tool that allows you to get a raw log and turn it into the end product, no other tools needed. Turning gives great satisfaction and is very relaxing. If money are an issue keep an eye on olx and you could find some great deals from time to time. I recently got a British made wood lathe for only 50 bucks.

[@sedenter]

+The Small Workshop Thanks, until now I tried to buy only new tools so I can be sure that they were treated well :), but I think this time I'll follow your advise and acquire one this way, cause I'm a little short on money for the moment :). Whish you all the best! I liked and shared your every video. Waiting for more!

[@kenbellchambers4577]

Great stuff, thank you from a recycling maniac. I love aluminum sheet cut from coke cans and plastic sheet cut from milk bottles.

[@danielm9062]

you know you could use the bigger aluminum cans for your tube like power drinks or beer cans I save all that it would work great

[@alz123alz]

brought a food grade plastic sheet for over 100 dollars ten years ago. Imagine what they must cost now.

[@vernwallen4246]

I hope my grand kids see this so they will know how we spend our spare time!! lol!!

[@JohnDoe-gm5qr]

It seems to turn nicely on a lathe, making all those thin ribbons.

[@Alatinu]

Thank you VM for sharing . Brilliant Super ecological your invention !. Best Regards from South America!. Well come your new videos. Good Luck! for a better future for "our home" : our planet!

[@JourneyToTheTruthandTR]

We can use this idea to make plastic bullets to help with our fight against Magneto. Thanks!

[@kjamison5951]

LOL!

[@The4362mont]

Very nice. Not some abstract useless tip but rather a very specific application that you can then apply to your needs. Need a pulley? Make it yourself from the recycle pile. Well done.

[@Ratchet4483]

Just wondering, what will happen if one tries to melt hdpe using furnance for melting aluminum?

[@DiesInEveryFilm]

Another great build

[@TheSmallWorkshop]

Thanks!

[@shigatsuningen]

HDPE does flow well if you heat it more. Be ware of overheating though as it can cause breakdown of the material after completing a part. Especially it tends to affect UV tolerance and then affect structural properties after this if one overheats plastic. I welded an HDPE box at home with a soldering gun producing come 450 degrees temperature and it becomes fluid, clear smelling like candle wax. You should be ok with turning the oven up to 220 degrees C max (that is 428 F for the metrically challenged in the audience). ;) Some tips collected on temperatures for plastics PP => 220-240 C (428-464 F) PE => 265 C (509 F) TPO => 445 C (833 F) HDPE => 220 C (428 F) Many claim HDPE should be melted at max 175 C but professional plants use 220 C. Formulae for conversion of temperature: (220°C × 9/5) + 32 = 428°F The viscosity of a plastic should decrease with higher temperature. Viscosity is a measurement not of how fluid it is but how sticky it is due to internal friction in the material. Thus, high viscosity => less fluidity.

[@marijanabrezic8854]

can you try melting pe - ld? it kinda came to my mind cause its probably rare plastic. but keep up the good work mate.

[@DirtCheapMeals]

The Picket Piece of a picket fence (not the post or the backer rail): Build a rectangular black metal box that has a mold of a picket fence piece at the bottom. Fill the box with chopped up plastic. Tilt the box and direct a series of Fresnel lenses onto it, with most heat directed towards the bottom of the box with the mold area. Place a 100 lbs weight at the top of the box to press the melting plastic into the mold. Get a tan while it's cooking. Remove the mold at the bottom and you should find a picket fence piece.

[@uweabraham3588]

Creative use of hdpe plastic! Thanks!

[@kjamison5951]

And the shavings ... can be recycled! Win!

[@alikasim9627]

Hi i solder plastic repair with soldering iron. What filter type should i use that can store the dangerous fumes from going out in the environment?

[@AndTheCorrectAnswerIs]

Reminds me of an old Warner Bros. cartoon where the Acme toothpick company turns down a whole tree to make 1 toothpick.

[@vern8890]

Awesome! Who needs a 3D printer!

[@drmkiwi]

Thanks for the warnings. Great idea / vid.

[@John-gm8ty]

Wow, I didn't even know this was possible, excellent video.

[@BUSTRCHERRI]

Not all plastics though. Only some.

[@juliodifelippo]

Excellent idea! Thanks for share!

[@commando340]

very interesting, and informative. thanks, for posting.

[@christopheleblanc9175]

and all the turning scrap can be re melted for a another project,

[@fortj3]

Where else can you easily remelt your chips and use them again?

[@kingpen]

Very inspiring~!! It may help for future recycling to make a 2-part mold so that you don't have to continue peeling apart the mold, whatcha think~?

[@brukernavnfettsjit]

And you can even recycle the shavings :D

[@noskill52]

+Auarhau neverending recycle :D

[@funny1048youtube]

well you can recycle it numerous times but after about 5-10 times of melting it down over and over it starts to lose structural properties due to degradation however keep in mind that if you melt hdpe at the lowest temperature possible i used 300 instead of 350 this will allow that piece of plastic to be recycled many more times without losing strength

[@PiefacePete46]

You can even recycle the pulley if you need a different size! :o)

[@aeoo371]

Dean Walcott If you could get your hands on some virgin resin and mix it 50%to 50% it would help. I worked in plastic manufacturing for over 30 years. I don't miss the smell of hot plastics.

[@goldbunny1973]

Have you ever looked at making 3d print filament using recycled plastics?? We're about to try it. If you have any helpful info on how we can strengthen/improve the filament I'd be interested to hear about it

[@QF2653]

I wonder if you could use a heavy duty document shredder to chop up the bottles? But your process seems like A LOT of work.

[@palac1229]

I really like your videos but I also like your lathe where did you buy your small wood turning lathe

[@AddictedtoProjects]

Awesome work! Very inspiring! Time to save those milk bottles and melt them down. I have been looking for a cheap source of larger diameter HDPE for turning on the lathe. This stuff is perfect! :)

[@Joshua79C]

Just make sure you do melt the caps and the seal ring as they are not the same color or even same type of plastic, unless you want that color and capable of mixing it by hand let alone extrude it to mix it.

[@jmikronis7376]

@@Joshua79C, I agree, the cap and seal ring is of a different type of plastic.

[@sagvan2989]

TO JE NÁPAD SUPERR DÍKY TI ZA INSPIRACI CO DODAT DOBRÁ PRÁCE :) Pavel ...

[@colutuber]

I would never have thought this could be done, great job. A multitude of applications. Can you tell me more about your tiny lathe, what and where did you get it? Thanks for sharing

[@TheSmallWorkshop]

Thanks, I'm happy you found it useful! Lathe is a Proxxon DB 250

[@alonzosanchez8577]

Great Video Please Keep Them Coming I Watch Every Single One!

[@TheSmallWorkshop]

Thank you very much!

[@gussferretti9665]

Impressive but how do you keep the hdpe pulley from spinning off the engine?

[@bikingmnviking3801]

Ingenious! Especially practical as I just bought a bunch of V belts, some of unusual sizes, that now I will be able to use because if I can't find a pulley in my collection I can simply turn it. Ever notice how great the turning community is?

[@Johnny241948]

If you have PYREX baking dishes or ceramic bakeware you can melt your hdpe as thick as the dish is and in slabs that can be cut to size and no sticking if you let it cool in the pan.

[@Joshua79C]

Yes and even a metal pan works, so long as it has no rings to prevent easy removal. I worked for a small recycling operation in 2005 at the time working with and making PE lumber.

[@SuperMirock]

Good workpiece!

[@TheSmallWorkshop]

Thanks!

[@mikelemon5109]

make some longboard wheels with it and see how it preforms would be nice to see a free solution replacing a quad set of wheels of 50$.

[@lukapenava8162]

+Derpy Herpy skateboard/longboard wheels are made from urethane

[@herve.c794]

it was too slippery

[@BUSTRCHERRI]

Too hard too slippery. Wrong material all around. Maybe could make a board from this plastic though with thin layers of fiberglass in between each later. Might be cool.

[@nick4leader]

Did washing remove the date stamp? I just don't want to contaminate if at all possible

[@ronyerke9250]

Did the shavings go back into your blue plastic tub for some future project? Nice pulley!

[@cael83100]

can modify, i wll use this for making motor

[@ticapix]

Great video. What lathe do you have in the video? (the small one)

[@moosefarms]

A strong cross-cut paper shredder could speed up the cutting process. We have a small one that's cable of shredding CD's (well... most of a CD), I'm sure it could handle a milk jug just fine. Thanks for sharing the video :)

[@CSSIandAssociate]

+moosefarms Good Idea. We have one of those also...

[@lilbro9469]

have you try put shoes in the Shredder?

[@funny1048youtube]

great job one suggestion that i have from experience is to mix the hdpe like dough into a gooey blob with oven proof gloves before you clamp it this will make sure there is no microscopic areas of stress between where the original flakes of hdpe

[@TheSmallWorkshop]

Thanks Dean, will give it a try, since I had a few holes in the final block of plastic.

[@funny1048youtube]

+The Small Workshop cool, hdpe is definetely a very versatile material

[@ellesmerewildwood4858]

Damn, that was brilliant !! Can you do this with the clear plastic soft drink bottles as well ? When you were compressing it the cylinder I didn't think it would compress into such a solid mass, I figured it would have voids. But in the end it was absolutely brilliant.

[@sumgai7]

Wrong kind of plastic.

[@Joshua79C]

PETE is recyclable but I would not recommend DIY remolding without first knowing its melting temps and flaming point, bud do remove the caps and safety ring as those are PP and are flammable not to mention will make that clear plastic turn green or whatever color the cap is and only a ounce worth in most instances. But not the same properties as PE as it is a weaker structure.

[@kevinm4225]

Love the video style man.keep it up!

[@orelygarcia]

Very cool . I have to try this. Thanks and thumbs up.

[@joylin6670]

Hi, Can I ask what is the material of the container that you used to mold HDPE?

[@gizzyguzzi]

Now, what is a good source of polycarbonate around the home?

[@Kukijiro]

Peter Brown makes a mallet head using this stuff. It's always interesting to see the uses for it.

[@TheSmallWorkshop]

Yes, I've seen that video. Most impressive melting process and use for HDPE I think I've seen on Randy Knapp's channel, he melts buckets and makes slingshots. He makes such nice looking sheets of HDPE I think you could make anything from them.

[@MetaView7]

a tall beer can, or a caffeine drink can, would make very good melting molds.

[@lancasterroentegen3170]

Excuse my French, but that's bloody amazing

[@BUSTRCHERRI]

This type of plastic can be fused incredibly easy as well if you have the means for forcing the two pieces together and holding it while it cools.

[@assassinlexx1993]

If you don't have a press. Make your mold and use your car to drive on the mold. Have a coffee then drive off the mold.

[@dwightsteffanson4574]

Milk jugs break down in the sun, will HDPE hold up long term? Is the HDPE in a kayak different than the HDPE in a milk jug? Well, obviously, but is a milk jug a suitable patch material?

[@YknotLearnall]

What little lathe was that that that you first turned the plug on?

[@MichaelLawing]

That's awesome and something I've been meaning to try. What kind of container were you using as your crucible there?

[@bulletproofpepper2]

I didn't see a reply so I thought I chime in with a best guess. It looks like a tall red bull aluminum can cleaned up.

[@The4362mont]

I'd go with spray can of some kind. Red bull can is aluminum and has no welded base like this can did. Steel can is my guess.

[@siegfriedobrabender4215]

You did a great job on making that pulley! I just wanted to know how well does it stand up to the caused by friction on that vee belt? Thanks!

[@TheSmallWorkshop]

I don't know, I've sold that lathe soon after I finished refurbishing it.

[@hhocar]

@ 2:16 : I wonder what I can do with this? @ 3:39 after chipping away on about 6" of material I end up with this 3" pulley. I say it's worth the effort if you have the lathe. Thank you

[@jacquesquartier1993]

Isnt it highly toxic ? I mean by heating PE, i thought there was Sb created by catalyst reaction

[@cornfusedatbest6693]

True craftsmanship is a dying "ART!" Please keep your videos coming. As of this date 5/15/16, there are 36 thumbs downers. My guess is, little Timmys dad doesn't want to admit how much $$$$$$ he spent on an education that does NOT compare to a man and his wits. Yes, this IS a dig on all you so-called engineers that should have taken classes in the agricultural field, as people will always have to eat.

[@InsideOfMyOwnMind]

Gary Kovach lol you forgot to mention: UNEMPLOYED engineers.

[@valveman12]

Sounds like you were never smart enough to be an Engineer. Too Bad!

[@masonfreeman4857]

I like your recycling plastic thanks for video

[@bearsoundzMusic]

how fluent can it get? It look less that 'melted'. If it could become a fluid, there would be much more usages for this. Think molding in silicone, f.i. fishing lures or plugs, but can it be made pourable ?

[@AnimooBobba]

The most violent use of scissors ever.

[@kaziklu79]

Great job as usual!

[@TheSmallWorkshop]

Thank you very much!

[@Redleafs2022]

Great! When new video come?

[@AlBarathur]

Its a great project and awesome idea. I wonder however, if the belt slips or the load is heavier, that pulley might just melt on the surface.

[@Joshua79C]

PE melts in the 120-180° C or 248-356° F range. I worked for a small company that made lumber from recycled PE back in 2005 and that is the melting range for it.

[@jimmatrix7244]

Have you done stress or heat test before it deforms?

[@John-gj1jr]

I know everyone removes paper labels, but what about painted labels? A lot of HDPE that could be used is practically covered with paint.

[@joebutin698]

Just a thought...a small crosscut paper or document shredder to help speed up processing the empty containers. Might go faster.

[@Joshua79C]

not sure most could even handle the handle portion.

[@harrynewell912]

Very nicely done!

[@davidbrousseau4591]

Excellent job, I'm going to do this tomorrow. How did you get the pulling to stay on the motor shaft? I have to make one for my belt disc sander. Great work thanks for sharing. Thanks for the Video. David

[@TheSmallWorkshop]

The motor I used was designed for friction fit, it has some sort of knurling on it. So I just drilled a slightly undersized hole and hammered the pulley in place. It sits just fine. For most shafts you should make a key of some sort, or a set screw, or a pin through the shaft, depends.

[@davidbrousseau4591]

Thank you for advise I appreciate it.

[@troyna77]

Imagine if you were able to process(without becoming toxic) this plastic and print parts that you need around the house.

[@kennethyoung141]

Would it melt into cogs and gear molds?

[@pappawheely]

are there any fumes to avoid ? and dust, I wonder

[@лерычк]

Интересный вариант.

[@rra022001]

288 numnuts dont want you wake people up. This is excellent engineering.

[@67cudaksa34]

how did you hold the pulley on the shaft, a key or set screw?