The beetle gets a shell

OK, after the frame is finished, it was time to roll some tube. I used a simple tube roller (Harbor Freight Tools) to help (see it in the background, attached to my welding table). It helps to have a set of extra hands, especially with a long roll. So, I recruited my son and his friend to guide the tube while I turned the wheel. I used three sections of 1-inch tube to create the shell. A few welds later and a graceful form was born.

Adding legs to the rolling ball sculpture

After the frame is complete, the next step is adding the beginnings of the insect's legs. These are important. The full weight of the piece will shift to each of these six legs. So, good welds and proper placement are crucial. In this photo, the leg sections are made from 1-inch round tube. The lower sections of the legs will be added soon.

Adding strength to the frame

After the twin frames were made, I proceeded to add blocking to tie the pieces together. Smaller sections of 1-inch steel tube secure the larger frame pieces. The length of the frame is about 9-feet in length and is 2-feet wide.

Welding up a pair of frames

The base of ‘Roly Poly’ needs to be strong. I cut and welded several pieces of 1 1/2 steel tube. Much of the sculpture will be attached to the base. I think of this like a foundation. It needs to be level, square and close to perfect.

Fresh steel arrives for rolling ball sculpture

Nothing like the sound of a big truck pulling up outside the shop to drop a bunch of steel. Another early morning delivery of the good stuff. This material will be used in the fabrication of ‘Roly Poly’, an interactive rolling ball sculpture. Bar stock, square and round tube and sheet metal will be used.