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The First Interaction: Why Doors Matter A door is more than just a barrier; it is the physical handshake between a human and a structure. In the world of high-end DIY, a secret garage housing a DeLorean demands an entrance that sets the tone for the madness within. This project aims to build a mechanical statement piece—a 200kg steel door featuring a complex gearing system that transforms a safety triangle logo into a glowing Flux Capacitor. This guide covers the fabrication of the "Doorean," moving from raw steel to a synchronized locking mechanism. Tools and Heavy Machinery Building a machine this substantial requires more than a standard toolbox. You need precision for the gears and brute force for the frame. * **Machining:** Optimum Mill, lathe, and a pillar drill. * **Fabrication:** TIG welder, mag drill, and a Swift-Cut Pro plasma table. * **Precision Cutting:** Wazer water jet and a CO2 laser cutter. * **Components:** Spur gears, thrust bearings, and delrin (acetal) for bespoke gear teeth. Step 1: Geometry and Gear Reduction Everything starts with a plywood template of the door opening to ensure a perfect fit. Once you have the shape, focus on the torque. A central valve wheel serves as the primary input. To make the heavy locking pins move with smooth, deliberate action, you must step down the speed using a series of spur gears. Bore out the centers of your gears on a lathe to fit your shafts. If the gears have uneven hubs that wobble in a three-jaw chuck, use a bandsaw to remove the bulk of the collar first, then finish the face on the lathe. Use an **optical punch** to mark your centers on the steel backing plate. This tool allows you to look through a magnifier to align a crosshair perfectly before striking the metal, ensuring the gear teeth mesh without binding or excessive play. Step 2: The Flux Capacitor Transformation The heart of the Doorean is a three-point linkage system. By mounting gears to a central "flux triangle," the rotation of the main wheel causes three arms to extend outward. This creates the iconic Y-shape of the Back to the Future time machine component. For the large bespoke ring gear, material choice is vital. While a Swift-Cut plasma cutter is fast (20 seconds), the Wazer water jet provides a much sharper tooth profile. However, for low-friction and durability, laser-cutting delrin provides a superior finish that integrates well with metal cogs without the need for heavy lubrication. Step 3: Frame Fabrication and Locking Pins You cannot bend 50mm box section into a tight radius without it creasing and looking like a disaster. The workaround is to use two 50x25mm sections. Roll them individually on a **swag roller**, then weld them together. This maintains the structural integrity and the aesthetic of the thicker tubing. To translate the circular motion of the gears into linear locking force, use a **milled slot system**. Mount the locking pins into the door’s side frame. The internal arms feature a small bearing on a spring; as the arm rises, it slides into a slot on the pin, forcing the steel bolt into the wall. This requires precise milling on an Optimum Mill to ensure the pins don't jam under the door's own weight. Tips and Troubleshooting * **Friction Management:** Metal-on-metal gears will grind. Cut thin **vinyl discs** to sit behind each gear to act as a low-friction shim. * **Wiring the Lights:** To avoid wires tangling in the gears, use the door itself as the ground. Mount batteries in a plastic shell on the rotating assembly and use **spring-loaded brass pins** to make contact with screws at the "locked" position. This completes the circuit and fires up the LEDs only when the door is fully engaged. * **Weight Distribution:** A 200kg door will rip standard hinges out of a wall. Fabricate three bespoke heavy-duty hinges and use a winch to position the door during installation. Conclusion The final result is a mechanical marvel that weighs north of 200 kilos but operates with a finger's touch. When the valve wheel turns, the gears hum, the Flux Capacitor glows, and three massive steel pins bite into the frame. It transforms a simple garage entrance into a piece of industrial art, proving that with enough steel and a bit of DeLorean inspiration, you can build something truly mega.