Tech/maintenance Making parts you can’t find.

[PigSquealer]

Time to check against the pattern sample.

This area below will be hand fit in place.

 

[PigSquealer]

Hand fitting was done using jewelers files at all contact areas. The tip extension by tenon will be trimmed later.

Loosely placed / not soldered.

I estimated two hours for making the part. That was spot on. Fitting took another half hour and I still need to solder it on.
That process can be viewed here Saxophones - Pork Tales: Saxophone Repair DIY Adventures.

 

[PiccoloPirate]

Making parts you can't get as well as making things/parts that don't exist, though you might know what they look like, as in Unicorns.
So to create the left side of this thumb rest handle, the master is shaped by hand, and to duplicate, on a manual carving machine, both the master and copy material, must be rotated 90 degrees.
Area between the red lined requires this.
Two 8"x 8"x 3/4" plates are bolted and glued together.
1/4" holes will be drilled at 20 degree intervals.
Each plate is mounted on a 5"x 5"x 1/2" aluminum angle stock.
Two 3/8" holes to mount each plate to the angle stock and two 1/4" holes for each plate, so they can be rotated and be aligned.
Master and copy material, can be mounted various ways.
IIRC these might be called indexing plates?

 

[PigSquealer]

Making parts you can't get as well as making things/parts that don't exist, though you might know what they look like, as in Unicorns.
So to create the left side of this thumb rest handle, the master is shaped by hand, and to duplicate, on a manual carving machine, both the master and copy material, must be rotated 90 degrees.
Area between the red lined requires this.
Two 8"x 8"x 3/4" plates are bolted and glued together.
1/4" holes will be drilled at 20 degree intervals.
Each plate is mounted on a 5"x 5"x 1/2" aluminum angle stock.
Two 3/8" holes to mount each plate to the angle stock and two 1/4" holes for each plate, so they can be rotated and be aligned.
Master and copy material, can be mounted various ways.
IIRC these might be called indexing plates?

View attachment 38014

View attachment 38017

Is this a saxophone thumb rest ?
Interesting setup. Lots of work for a one-off or is this for a production run ?

 

[PiccoloPirate]

Handles for archery/bows and air pistols.
Prototype idea was made for an improved two hand hold on a powder burner,
the S&W 460XVR.
Been a three fingered archer for almost seven decades, 20yd range in backyard.
Indoor and outdoor 10 meter air pistol range. 🎯
Great upper body workout and a concentration discipline.
Like riding a motorcycle in traffic.

Water hazards on and off the Links 🙄

 

[PiccoloPirate]

Small production run at first.
CNC for wood and wood/epoxy laminations and licensing for rubber like materials to follow.
Current wood undercutting and 45 degree bevel fixtures on mill with Kutzall burrs.

 

[mark_addy]

With the part edges squared it’s time to make them straight and level. For this I sandwiched the part in between wood blocks. This being positioned just above flush. @mark_addy the files are out now.
View attachment 37993
Work down the high spots.
View attachment 37994

Then burnish.
View attachment 37995
Repeat on other side.
View attachment 37996

I like your 'Jeweller's Peg' up a bit on the thread. Every time I see one I think 'that would be handy' and then forget about it again 🙂

 

[PigSquealer]

I like your 'Jeweller's Peg' up a bit on the thread. Every time I see one I think 'that would be handy' and then forget about it again 🙂

Handy tool I make from 1/2” scraps.
See if you can print this @ 100% ?

 

[turf3]

Handy tool I make from 1/2” scraps.
See if you can print this @ 100% ?
View attachment 38031View attachment 38032

I wouldn't call that a "jeweler's peg" I'd call it a "fishmouth" and I can't see why anyone who can do work for which it'd be handy wouldn't just cut it out of a piece of wood with a coping saw like you did. At least 75% of the stuff people say "3d print it" can be made faster and easier other ways. (The other 25%, though, will save your bacon when it comes up.)

 

[PigSquealer]

I wouldn't call that a "jeweler's peg" I'd call it a "fishmouth" and I can't see why anyone who can do work for which it'd be handy wouldn't just cut it out of a piece of wood with a coping saw like you did. At least 75% of the stuff people say "3d print it" can be made faster and easier other ways. (The other 25%, though, will save your bacon when it comes up.)

A generic description of a bench tool. No rules design. Who said anything about 3D printing ? Print the drawing. The ruler is for scale to check at 100%.

 

[mark_addy]

A generic description of a bench tool. No rules design. Who said anything about 3D printing ? Print the drawing. The ruler is for scale to check at 100%.
View attachment 38033

Ah - I have one of those slightly crappy folded-up mini G-clamps which I suppose I could employ for just this purpose. I inherited it from my late F-in-L about 25 years ago, and I might not have 25 years left to put it to something useful!

 

[PigSquealer]

A handy chart for wall art.

 

[mark_addy]

A handy chart for wall art.
View attachment 38061

That's useful, given the number of USA instruments around here. Here, we generally see BSW (BS Whitworth, which is coarse), BSF (British Standard Fine), BSP (BS Pipe, also known in Europe as 'G' for Gas) and of course 'normal' metric and then various types of Metric Fine. Oh, and BA (British Association) which is small and metric, kind-of, masquerading as being not-metric - very common on old electronics / radios / test instruments etc. I think we call your NC and NF 'UNC' and 'UNF'; both are unusual these days and only UNF turned up reliably (in my limited experience) on older automotive hydraulic brake fittings - maybe those were bought in from a US company (Girling?) post-war and it stuck. That flipping Chinese oxy-propane torch was 'your' NPT, but is now 'our' BSP - and it works without drama, thank goodness.

On my own instruments, I foresee re-tapping things for BA where stripped because I have full sets of taps and dies (the normal sizes run downwards in small increments from about 1/4" - 0BA - down to 'I think I'm going to break this tap' - 12BA) and loads of fasteners. That's probably sacriledge, but I only desecrate my own posessions.

 

[PigSquealer]

On my own instruments, I foresee re-tapping things for BA where stripped

Flash inside of hole with solder and re-tap proper. Will be 2.5-.45 or 2.6-.45

 

[mark_addy]

I might even have an M2.5 tap. It would be wilfulness (is that spelt right?) to go for 7BA, not least because I might have the taps and dies but almost nobody uses the odd-number sizes for anything anymore - probably why someone gave them to me!

Some of what are called 'French' in your table, we call 'Metric Fine' - M8x1 is all over my Russian motorbike, in places (nuts and bolts, threads in steel) that a Brit bike would use BSF. I bought half a box 20 years ago and I still have quite a few now.

My 'American' 3C collets seem OK (made it back home - in a storm, motorway wash-out, flooded lanes and all that, 6-1/2 hours for 220 miles)- Chinese, but that's inevitable with what I paid for them. So they crossed the Pacific, and now they have done the Atlantic too. I'm too tired to set things up and measure run-out just now!