Thumb wheel jig

Jig & threaded blank
knoba - thumb wheel jig

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Freshly machined thumb wheel blank
knoba - thumb wheel jig

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knoba - thumb wheel jig

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Screw blank on underside of jig, locknut it, drill through one hole, use lock pin (silver coloured part), drill through other holes, deburr, fettle & smooth thumb wheel.
knoba - thumb wheel jig

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Nice!
knoba - thumb wheel jig

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knoba - thumb wheel jig

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What’s in the CAD file…
knoba - thumb wheel jig

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Materials:
1 x 60x60x16 mild steel plate
1 x M12x80mm bzp bolt
1 x M6x40mm 12.9ht Socket cap bolt
1 x m6 washer
1 x m6 nut

1 x 13mmx32mm o/d, m6 threaded, 6 series Aluminium blank

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knoba – thumb wheel jig – 2018.dxf

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Garden hose wheel

A reminder of a younger life
knoba - garden hose wheel

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knoba - garden hose wheel

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knoba - garden hose wheel

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Chainsaw horse

Made from recycled wooden pallets, folds flat.
knoba - chainsaw horse

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What’s in the CAD file…
knoba - chainsaw horse

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Materials:
3 x wood fork lift pallets;
12 x 115x92x16mm
8 x 114x70x16mm
24 x 2 1/2"x10 stainless wood screws
3 x m10x80mm stainless coach bolts
3 x m10 bzp nyloc nuts
6 x m10 stainless penny washers

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knoba – chain saw horse – 2018.dxf

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Bobbin spool keepers

Threads on bobbins, threads on spools, all very messy.
knoba - bobbin spool keepers

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stick is cut & lacquered, hair band is cut & wire wrapped at top of stick, bead is glued on, loop is made with small crimp in end of hair band.
knoba - bobbin spool keepers

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Neat.
knoba - bobbin spool keepers

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knoba - bobbin spool keepers

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What’s in the CAD file…
knoba - bobbin spool keepers

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Materials:
Per item;
1 x 100mm nail stick (hoofer)
1 x 12mm wooden bead
1 x elastic hair band
1 x 2mm i/d crimp (bead/electrical)
wrapping wire
pva glue
varnish/lacquer

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knoba – bobbin spool keeper – 2018.dxf

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Bobbin sander mods

Table inserts to replace the plastic ones (hole between sandpaper & table)
knoba - bobbin sander mods

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Machined table inserts (made with holesaws & angle grinder), from plate
knoba - bobbin sander mods

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Pickling overnight in sulphuric acid to remove mill-scale from hot-rolled steel
knoba - bobbin sander mods

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The drop on this aperture is 3.5mm, my plate (same as the plastic inserts) is 3mm…
knoba - bobbin sander mods

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After pickling they are desmutted with detergent & a pan scourer
knoba - bobbin sander mods

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What’s in the CAD file
knoba - bobbin sander mods

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Printed 1:1, they make great stick on templates for more machining
knoba - bobbin sander mods

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Making a shim to fit into the aperture
knoba - bobbin sander mods

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Welding magnets placed on top
knoba - bobbin sander mods

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Thin bead of silicon sealer
knoba - bobbin sander mods

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Drop in shim
knoba - bobbin sander mods

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Drop in large table insert
knoba - bobbin sander mods

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Place magnets over hole & leave for 48 hours
knoba - bobbin sander mods

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Templates stuck, centre punched, pilot drilled & cleaned
knoba - bobbin sander mods

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Increased hole size to 6mm (1/4″) and countersunk both sides
knoba - bobbin sander mods

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Perfect. No more misaligned levels when sanding.
knoba - bobbin sander mods

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Was going to install small magnets but the inserts are fine
knoba - bobbin sander mods

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Added a basket for the bits & pieces.
knoba - bobbin sander mods

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Materials:
6 x 100x100x3 mm (4"x4"x1/8") plate/sheet mild steel
1 x 100x100x0.25 mm (4"x4"x0.010") shim mild steel
Silicon sealer

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knoba – bobbin sander mods – 2018.dxf

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Steel thumbscrews & jig

What I’m making: M8 wingbolt
knoba - Steel thumbscrews & jig

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Made these tabs to weld onto bolt heads (details in CAD file below)
knoba - Steel thumbscrews & jig

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Replacing these plastic ones (some have broken)
knoba - Steel thumbscrews & jig

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Stock used in making a welding & alignment jig (to help make the wingbolts)
knoba - Steel thumbscrews & jig

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Materials:
1 x 50x50x6 mm (2"x2"x1/4") flat section mild steel
2 x 50x25x3 mm (2"x1"x1/8") equal angle mild steel
1 x 100x14 mm (4"x9/16") hex bar mild steel

All pickled, de-smutted & deburred.
Jig copes with 6mm to 8mm (1/4" to 5/16") bolts

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8mm hole in centre (top side)
knoba - Steel thumbscrews & jig

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Countersunk 90° included angle (underside)
knoba - Steel thumbscrews & jig

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Marked all & drilled (8mm) holes in uprights
knoba - Steel thumbscrews & jig

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Going to plug weld (MIG) through holes to base
knoba - Steel thumbscrews & jig

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Using a wingbolt tab, as a spacer, wrapped in masking tape to add some clearance
knoba - Steel thumbscrews & jig

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Welded
knoba - Steel thumbscrews & jig

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Dressed with angle grinder flapwheel
knoba - Steel thumbscrews & jig

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Marked and sliced through only the angle iron sections
knoba - Steel thumbscrews & jig

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Cleaned up
knoba - Steel thumbscrews & jig

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Nuts, bevelled, threaded & marked. From hex stock
knoba - Steel thumbscrews & jig

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90° included angle
knoba - Steel thumbscrews & jig

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Different threaded nuts
knoba - Steel thumbscrews & jig

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Nuts hold the bolts in good contact & alignment
knoba - Steel thumbscrews & jig

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Tabs are centre marked, drop in with good alignment, ready for welding
knoba - Steel thumbscrews & jig

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What’s in the CAD file
knoba - Steel thumbscrews & jig

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knoba – steel thumbscrews & jig – 2018.dxf

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Wired edge dollies

Thanks to billsmetal – youtube. Cut & pickled materials…
knoba - wired edge dollies

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How they will fit together
knoba - wired edge dollies

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Bevelled one edge for easier weld penetration
knoba - wired edge dollies

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Strong, flat heatsink (bench) & clamps to restrict distortion
knoba - wired edge dollies

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Gouged the rear of seam & welded to give homogeneous fusion
knoba - wired edge dollies

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Cleaned up with flap wheel & belt sander.
knoba - wired edge dollies

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Materials:
1 x 20x32x50mm mild steel, Rectangular solid section
1 x 25x38x50mm mild steel, Rectangular solid section
2 x 25x3x50mm mild steel, Flat section
2 x 50x6x50mm mild steel, Flat section

Normalise & harder alloy for upgrades.

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