Making Plastic Rod Stock - Melting HDPE Milk Jugs

[@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

[@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.

[@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.

[@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...

[@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 :)

[@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.

[@DylansDIYWorkshop]

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

[@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!

[@JourneyToTheTruthandTR]

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

[@kjamison5951]

LOL!

[@TalmadgesArcade]

I was searching how to meltdown milk jugs and stumbled across this without really reading (understanding) the description. When you said stock I thought you meant filament for a 3d printer. I started the video and thought "oh great another video with no narration" (people hate those) I was tapping right arrow, jumping through the video and when I saw the original part you were copying I just thought it was more material which was being melted down. You got to the part where you put it in the vice and knock off the wood plug and I thought "meh, that quality kinda sucks." And then you started turning it on the lathe and my eyes bugged out. Wow man, just wow, nice work making an identical match to the original wheel. Awesome job! Watching this made my day. Thank you for sharing.

[@DrLumpyDMus]

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

[@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.

[@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.

[@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.

[@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!

[@silvermaple7779]

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

[@TheSmallWorkshop]

Thank you too!

[@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!

[@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.

[@TreasureByMeasure]

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

[@kjamison5951]

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

[@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

[@uktony1525]

Brilliant project, recycling at its very best.

[@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 :)

[@michaelj2439]

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

[@XXCoder]

Thanks for adding clear text, makes everything clear!

[@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!

[@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

[@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?

[@vern8890]

Awesome! Who needs a 3D printer!

[@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.

[@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.

[@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.

[@jeffbeck6501]

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

[@lancasterroentegen3170]

Excuse my French, but that's bloody amazing

[@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.

[@rra022001]

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

[@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.

[@raiderman28]

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

[@vernwallen4246]

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

[@AndTheCorrectAnswerIs]

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

[@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.

[@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?

[@GaryTruesdale]

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

[@ronyerke9250]

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

[@seanswanson.2919]

I love your work I have made so much because of you

[@TheSmallWorkshop]

Thanks Sean, happy to hear that!

[@seanswanson.2919]

+The Small Workshop love it thank you for replaying

[@paulstuartwilson485]

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

[@TheSmallWorkshop]

Thank you too Paul!

[@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

[@RickRose]

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

[@hansdegroot8549]

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

[@kafeltz]

I enjoyed watching this.

[@TheSmallWorkshop]

Happy to hear that!

[@John-gm8ty]

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

[@BUSTRCHERRI]

Not all plastics though. Only some.

[@nick4leader]

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

[@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

[@1lupus]

Good video I use red Coca Cola bottle tops to make replaceable heads for my soft face mallets. I use a soft drink can, compress with an arbor press and then finish on a woodlathe. I think the downvoters could be people who automatically head for the downvote button when music comes on in a video. At precisely one minute fifty I was about to click and the music stopped thank goodness.

[@TheSmallWorkshop]

I use music when I'm filming and watching the kids at the same time. To cover their voices/toys and also the TV sound, to avoid copyright problems. I know it's annoying, but can't find a way around it.

[@1lupus]

I understand. One commenter had wondered why a certain number of people had clicked dislike. I am merely offering an possible answer. It is like the hardware shops here in Oz they always have a cheap mono speaker up near the roof with horrid music, a lot of people don't get riled enough to complain, a lot of people seem to enjoy it they actually whistle along to the music while you can over hear some people saying lets get this done and get out of here and obviously distressed. I understand it is not everyone who hates Muzak, and the horrid intercom that keeps telling Brad that he is needed at the loading bay, You can't please us all. Thanks again for the videos.

[@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.

[@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.

[@tymz-r-achangin]

Thats pretty cool and we know youre making that part as more of a one-time job for a pulley on a motor, but we need to make a 10mm plastic (real close to 3/8 diameter and probably 1 foot lengths or longer) and we dont want having to destroy our mold each time that we make each rod. Would think is there some sort of release agent that can be applied to the mold that after heating up the plastic, the rod will then slide/press out of the mold? What we're doing is making our own wads for a special .410 slug Oh and nope we're not going to spend mega amounts of money to build our own plastic injection machine and then the very expensive costs of a shop to machine the molds, and nope we're not going to go back online to buy the plastic round bars. We need a total of around 70 feet of it and we're not going to be gouged on the cost of what is often times mere recycled plastic that they extrude from a dye by the miles of it

[@CtrlAltRetreat]

Si grease release agent works on hdpe. Good luck mate. Though if you're doing this for wads, why not a stack of cardstock discs? I've always liked cardstock or mdf discs and they'll drop away a lot faster too

[@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?

[@jimmatrix7244]

Have you done stress or heat test before it deforms?

[@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.

[@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

[@JohnDoe-gm5qr]

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

[@uweabraham3588]

Creative use of hdpe plastic! Thanks!

[@palac1229]

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

[@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.

[@Sascha_LB]

Cool project. Thanks for showing. Is there any smell during the melting process?

[@TheSmallWorkshop]

Not really, mostly just a vague smell of warm plastic.

[@jmikronis7376]

@@TheSmallWorkshop, does it set off a smoke alarm as found in common mobile homes?

[@sagvan2989]

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

[@michaelb.5345]

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

[@kevinm4225]

Love the video style man.keep it up!

[@AnimooBobba]

The most violent use of scissors ever.

[@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~?

[@kaziklu79]

Great job as usual!

[@TheSmallWorkshop]

Thank you very much!

[@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.

[@ticapix]

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

[@commando340]

very interesting, and informative. thanks, for posting.

[@DiesInEveryFilm]

Another great build

[@TheSmallWorkshop]

Thanks!

[@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?

[@masonfreeman4857]

I like your recycling plastic thanks for video

[@xandertsaint8717]

Will a paper shredder mill that stuff ???

[@ronaldlogan3525]

Yes, boys and girls, mom's sewing scissors have many practical uses.

[@alonzosanchez8577]

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

[@TheSmallWorkshop]

Thank you very much!

[@Dailymailnewz]

Man your fingers went very near to that stuff, always safety first no matter how experience you are. Over confidence can cause allot of trouble. Always wear hard clubs for such a job.

[@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!

[@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?

[@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.

[@jacquesquartier1993]

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

[@ZTTINGS]

Crosscut shredder could maybe save you time in the beginning?

[@pappawheely]

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

[@watahyahknow]

looks like its worth the trouble of melting those jugs down how resistand is the plastic to wear ? i immagine its pretty soft even in stick form

[@Joshua79C]

If you ever use a plastic cutting board, likely made of a grade of PE, factories or fulfillment centers with conveyors use sheets of PE to make the belt slide along smoother and last longer.

[@Wwturb]

Nice vid. What do you do with the shavings afterwards to prevent Micro Plastic pollution in water.?

[@nicstr28]

He ships it on the USS A.O.C. to Willy Wonka's plastic factory to be used in high speed rail tracks to Hawaii and turbine fans for the Electric Airlines

[@gussferretti9665]

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

[@orelygarcia]

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

[@simonhopkins3867]

Very cool can I ask was there much of a smell while melting it ? Thanks Simon

[@Joshua79C]

Only if you over heat it will you get an unpleasant smell.

[@Ratchet4483]

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

[@bruceclothier8238]

When you first removed the cylinder from the tin can, the surface was pockmarked. Other people have found the same. Were there holes deeper down or was it homogeneous?What was the motor - it looks like a fractional horsepower induction motor. What was it salvaged from. And how did you fix the pulley to the motor shaft?

[@TheSmallWorkshop]

In some areas the holes were deeper, I had to avoid them. Motor was salvaged from an old washing machine, it's 1/2 hp. The pulley was friction fit since the motor shaft had some knurling on it.

[@pmm4177]

have you ever thought of using an old food processor to chop up the hdpe into super tiny pieces?

[@TheSmallWorkshop]

I've heard of it done by other people so is should work. Unfortunately I already gutted my old blender to get the motor out of it a few years ago. Plus I don't do this too often.

[@harrynewell912]

Very nicely done!

[@Justone177]

Okay, I read the one comment on the OLX lathe, now I need more! What should I look for should I want one like yours?

[@TheSmallWorkshop]

Mine is a Proxxon DB 250.

[@juliodifelippo]

Excellent idea! Thanks for share!

[@gginnj]

You really should have a well ventilated kitchen if your going to melt plastic in the oven, the fumes can be hazardous. The hood fans may not be enough, often all they do is filter smoke and grease but vent back into the kitchen. It most likely won't kill you, but if you have asthma, it may get you wheezing.

[@TheSmallWorkshop]

Plastic is such a generic term. It can be rather harmless, like polymer clay, or very dangerous, like PVC. From what I understood, reading online, translucent white HDPE is on the harmless side, as long as you keep the proper temperature. Anyway, I have a well ventilated kitchen and the hood takes the air outside. Also I only did this once, to see if it works, then I bought a dedicated shop toaster oven that will be used on the outside patio.

[@Joshua79C]

I melted plenty of PE into lumber pieces for small recycling operation back in 2005, never had my asthma act up on me despite it was done under a sheltered area at the time before the operation was moved to a more enclosed shop after I was let go and worked where I got better paid a for my other talent skills