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  1. #61
    Join Date
    Jun 2010
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    Bundaberg
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    54
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    3,402

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    Quote Originally Posted by Mountain Ash View Post
    Hi CT. Looks like a bright and sunny spot to get your peening done. You're not locked away in a workshop?
    Most of the handwork on this build has been executed sat outside at a table on the deck, only the hacksawing and drilling has been done in the shed. About a year ago I laid a 7m x 7m slab under my carport and set it up as an outdoor workshop so now the shed is mainly used to store the machines. I definitely prefer working outside when I can with the natural light and a nice breeze.
    Nothing succeeds like a budgie without a beak.

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  3. #62
    Join Date
    Jun 2010
    Location
    Bundaberg
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    54
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    Today was a washout...

    I marked out the lever cap (only 30mm by 5/8” ) on my last remaining bit of 6mm thick stainless. I decided the best plan of attack would be to drill and tap the hole for the thumbscrew then cut and smooth the sides so that the pivot hole could be drilled through before refining the overall shape. All went well right up until I snapped my only tapered M4 tap. My intermediate tap couldn’t be found anywhere and my bottoming tap turned out to be blunter than a sackfull of wet mice . No idea how this became blunt; it’s not like I’ve tapped thousands of holes with it... but then again the set was branded “P&N” so the first turn probably killed it...

    So before I became dangerously frustrated I decided to knock it on the head. I’m back at work tomorrow and won’t be back until the beginning of December so that’ll give me time to order a new set of M4 taps (English HSS hopefully!) and work out the most pleasing shape for the rear handle.
    Nothing succeeds like a budgie without a beak.

  4. #63
    Join Date
    Jun 2010
    Location
    Bundaberg
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    54
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    Default Back on it...

    Ok, so I’ve been home for a week now but with all the festive preparatory nonsense today has been the first day that I could spend some quality “me” time. I took the lever cap blank to work with me and finished off tapping the hole so all I had to do on my return was cut it out and shape it. First part was to shape it into a rectangle with all sides square:
    331A44DE-7EC2-4B69-85DB-0BFBEBE53190.jpg

    Then the hole was drilled for the pin to go through and the whole shebang assembled with a blank blade to ensure that the geometry was correct:

    62F53FEA-C60E-45FF-9F2C-D5A9A8591133.jpg 25267EBD-895F-4B15-AECC-F614C38C3323.jpg

    Success!

    Everything lined up correctly and square so the next step was to rough out the curves:

    5D6BBEF7-8078-4244-95D6-A50ADA7A93CA.jpg

    And of course I had to fit it again to see how it all looks!

    B404BEDF-511D-48AC-BB00-9ABACAD562E3.jpg D948CF77-B0C7-4E99-86AC-A4032E3CB6F7.jpg F6843E20-BE5B-45E1-8B8E-CE8105ED30C7.jpg

    Next is a fair amount of cleaning up. I want to make the back of the lever cap concave and all the filed surfaces need abrading smooth with some wet and dry. Then I can peen in the pivot pin and finally clean up the dovetails and rivet heads.

    After that it’ll be time to make the rear handle. I’m thinking of a slender affair with a mushroom end similar to that used on a birdcage awl; what are your thoughts?
    Nothing succeeds like a budgie without a beak.

  5. #64
    Join Date
    Nov 2004
    Location
    Millmerran,QLD
    Age
    73
    Posts
    11,095

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    Chief

    That is looking good and so different. I may have to do something shortly on my effort.

    Regards
    Paul
    Bushmiller;

    "Power tends to corrupt. Absolute power corrupts, absolutely!"

  6. #65
    Join Date
    Oct 2010
    Location
    NSW
    Posts
    643

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    Lookin good chief. I hate to disappoint you but that rivet will never work like that. I'm not familiar with a birdcage awl but a mushroom shape sounds good to me.

  7. #66
    Join Date
    Nov 2011
    Location
    Melbourne
    Posts
    6,973

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    Looking great Chief.

    I think the mushroom end would look great, I also hope you keep the Pop Rivet, lever cap pin the way it is, it’s kind of different[emoji6].

    Cheers Matt.

  8. #67
    Join Date
    Jun 2010
    Location
    Bundaberg
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    Quote Originally Posted by Picko View Post
    I'm not familiar with a birdcage awl but a mushroom shape sounds good to me.
    A birdcage awl differs from a scratch awl in that the tip is ground with 3 or 4 facets; like a really long thin pyramid. They are used for marking and starting holes; a little bit like a gimlet but not designed to go deep. The mushroom head fits nicely in the palm and assists in pushing axially.

    And pictures are in short supply! I know that they are best shaped with a mushroom head but I could only find a couple of pictures online... and one of them is from Derek’s webpage. Every other online picture shows either a boring plain handle or a bulbous round one, but here is what I am thinking of replicating:

    1E4B4130-3259-4657-97C2-7DA52176E843.jpeg

    Now just imagine it with a 2-3 inch long tapering section between the mushroom and the ferule; that is what I am thinking of making.
    Nothing succeeds like a budgie without a beak.

  9. #68
    Join Date
    Nov 2007
    Location
    Lawrencetown, NS, Canada
    Posts
    587

    Default

    Looks great - can't wait to see the woodwork!

    Steve

  10. #69
    Join Date
    Dec 2013
    Location
    Mt Waverley Vic 3149
    Age
    81
    Posts
    679

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    Quote Originally Posted by Picko View Post
    Lookin good chief. I hate to disappoint you but that rivet will never work like that. I'm not familiar with a birdcage awl but a mushroom shape sounds good to me.
    Don't you hate it Chief, when to spend countless hours awake at night dreaming up alternatives for the use a common Pop Rivet. Just when you sort out not only how to use it backwards so that you can peen over the end which in 'normal' use would have snapped off and be thrown away, but you have left the 'rivet' end as a work of art and a tribute to the inventors of a component that sheet metalworkers wouldn't be without - then someone has to come along and declares that it will never work like that.

    You just have to keep it - I know you can make it work!!

    Cheers
    Bob

    A note to the judges - I expect you will all award the chief with extra points to compensate for the hours of lost sleep.(Bribe intended)

  11. #70
    Join Date
    Oct 2018
    Location
    Dandenong Ranges
    Posts
    1,865

    Default

    Hi CT. Looking back at the photos of the original, a mushroom knob to fit in the palm of your hand would be a definite improvement. The 4 sides of a birdcage awl are perfect for creating starter holes for screws that grab easily

  12. #71
    Join Date
    Jun 2010
    Location
    Bundaberg
    Age
    54
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    3,402

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    Finally got around to posting some more pics! I did the last bit of work last Monday but have been back at work since Thursday and lost my round tuit. This shift I’m only away for a week; I get home Xmas Eve to the delight of the cats who will have had to spend that time enduring the loving attentions of my rabidly festive Beloved. Have you ever seen anything more pathetic than a cat wearing an elf costume?

    Anyhoo, finished off the lever cap. 304 does polish up beautifully doesn’t it?
    09E9FBF5-6914-44B8-A49C-7EBCAA87B046.jpg

    Removed the excess bits hanging off; filed everything to size and gently hit it with a 120g belt. Next to it is the crucial pop rivet that several have taken a shine to; and a piece of ancient Irish bog oak that may become the stuffing. This was donated by Bdar and may be followed up with a wider piece for the handle.
    F234E4FB-BD6D-493C-8472-B08195442FA1.jpg

    Unfortunately I have a couple of blemishes on the sole . These were probably caused by a few mis-hits with the little toffee hammer during the peening process. Once the sole is cleaned up further I’m hoping they’ll visually diminish.
    FF755301-2E94-400E-813D-810291ECB3A3.jpg 05E71A51-1BD1-4FD7-A989-CE35FAC5A02D.jpg

    And I also have a tiny confession to make; I just wasn’t happy with only the 3 skinny rivets holding the back to the sides. As the handle is attached here I had visions of the back becoming loose; probably an unfounded worry but I chose to strengthen the joint further by running a tiny bit of silver solder down the edges. It is a practically invisible joint; once I’ve finished cleaning up the back I’ll post a picture.

    Anyhoo; that’s it until after Xmas.
    Nothing succeeds like a budgie without a beak.

  13. #72
    Join Date
    Jun 2010
    Location
    Bundaberg
    Age
    54
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    3,402

    Default Quick update...

    Haven’t had as much “me time” as I required during this break, but I’ve been putting it to good use. Namely in discovering how shockingly atrophied my woodturning skills have turned out to be...

    This is handle #3 (I’m not counting the two with the scars from skew catches) and is finally the overall shape I want; but currently too long. And maybe a bit fat in the bum.
    A11F9C5D-311B-42D6-B469-C7B7A1510614.jpeg

    I knocked #4 just before dinner which is about 5/8” shorter; and tomorrow I’ll turn #5 and possibly #6 until I’m satisfied that the size and shape are what I want. Then I get to make the final fitted handle from a piece of Ukrainian ancient bog oak; this is a beautiful piece of timber that I can’t risk damaging through sloppy tool control
    Nothing succeeds like a budgie without a beak.

  14. #73
    Join Date
    Nov 2007
    Location
    Lawrencetown, NS, Canada
    Posts
    587

    Default

    Quote Originally Posted by Chief Tiff View Post
    Haven’t had as much “me time” as I required during this break, but I’ve been putting it to good use. Namely in discovering how shockingly atrophied my woodturning skills have turned out to be...

    This is handle #3 (I’m not counting the two with the scars from skew catches) and is finally the overall shape I want; but currently too long. And maybe a bit fat in the bum.
    A11F9C5D-311B-42D6-B469-C7B7A1510614.jpeg
    I knocked #4 just before dinner which is about 5/8” shorter; and tomorrow I’ll turn #5 and possibly #6 until I’m satisfied that the size and shape are what I want. Then I get to make the final fitted handle from a piece of Ukrainian ancient bog oak; this is a beautiful piece of timber that I can’t risk damaging through sloppy tool control
    Well, I can handle how that's turned out,...

  15. #74
    Join Date
    Jun 2010
    Location
    Bundaberg
    Age
    54
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    3,402

    Default More practice on the lathe...

    Here are the trial handles I developed in order to a) determine the best fit and shape, and b) try to remember which end of the skew goes into the wood. Ouch.

    6F10120C-365C-4AEA-A656-1C93A1AD26C0.jpg

    I settled on the spotted gum handle as it fitted comfortably in the hand; it’s short enough so that the tool doesn’t topple on its back but remains long enough so that one’s knuckles don’t drag over the workpiece. The duds will end up repurposed into awls or similar.
    3253F78F-91E2-4536-BA7B-D8D1751BE8BB.jpg

    Now to turn this:D63E4AD6-07A7-4CA2-9B66-410CF5F6974E.jpeg into this: 935DFBD1-030B-4A9A-80FA-3328374C47AD.jpg I deliberately left the drive end square because that lump will be turned into the front bun.

    Sanding to 600 grit, wiping on a few layers of CA and polishing with EEE before breaking out the Shellawax turns this:

    3A933A01-D692-4859-BE99-B781BB8D843B.jpg
    into this!
    CC2BBB34-0AAB-44E3-A55C-4ED73C2796BE.jpg 5430AB5C-0274-4BAA-9DCC-A5BD7B5835F5.jpg

    Tomorrow I’ll run the gauntlet of parting it off and fitting the ferrule before carving out the front bun.
    Nothing succeeds like a budgie without a beak.

  16. #75
    Join Date
    May 2019
    Location
    Brisbane
    Posts
    807

    Default

    That's some serious prototyping. The final handle looks fantastic. Love the color.

    Sent from my SM-G950F using Tapatalk

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