Coil winder stick

Made from mahogany, for loading with magnet wire, 500mm long
knoba - coil winder stick

~§~

A 2a variac core in for rewinding
knoba - coil winder stick

~§~


Materials:
1 x 524x25x6 mm (20 5/8"x1"x1/4") hardwood
note: use (feet, 1/2 yard) if imperial measurements preferred!

•••

Advertisements

Chainsaw horse

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

~§~

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

~§~


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

~§~

knoba – chain saw horse – 2018.dxf

•••

Bobbin sander mods

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

Welding magnets placed on top
knoba - bobbin sander mods

~§~

Thin bead of silicon sealer
knoba - bobbin sander mods

~§~

Drop in shim
knoba - bobbin sander mods

~§~

Drop in large table insert
knoba - bobbin sander mods

~§~

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~


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

~§~

knoba – bobbin sander mods – 2018.dxf

•••

Steel thumbscrews & jig

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

~§~

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

~§~

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

~§~

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

~§~


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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

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

~§~

Welded
knoba - Steel thumbscrews & jig

~§~

Dressed with angle grinder flapwheel
knoba - Steel thumbscrews & jig

~§~

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

~§~

Cleaned up
knoba - Steel thumbscrews & jig

~§~

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

~§~

90° included angle
knoba - Steel thumbscrews & jig

~§~

Different threaded nuts
knoba - Steel thumbscrews & jig

~§~

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

~§~

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

~§~

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

~§~

knoba – steel thumbscrews & jig – 2018.dxf

•••

Spot weld tip shaper

Machined from 22mm o/d silver steel. Top side.
knoba - spot weld tip shaper

~§~

Underside.
knoba - spot weld tip shaper

~§~

Dremeled with diamond burrs.
knoba - spot weld tip shaper

~§~

Held at cherry for 6 to 7 mins.
knoba - spot weld tip shaper

~§~

The gauze, I was trialling, was only good for tempering.
knoba - spot weld tip shaper

~§~

Quenched, here.
knoba - spot weld tip shaper

~§~

Made to fit a thread die holder.
knoba - spot weld tip shaper

~§~

Finished piece. Can be sharpened on either side of cutting edge.
knoba - spot weld tip shaper

~§~

Link to CAD file below.
knoba - spot weld tip shaper

~§~

knoba – spot weld tip shaper – 2018.dxf

•••

Lab tripod

Made from 304 stainless steel.
knoba - lab tripod

~§~

knoba - lab tripod

~§~

It disassembles when not required. The tig’ed nuts are clearance drilled.
knoba - lab tripod

~§~

Silicon feet good to approx. 200°c.
knoba - lab tripod

~§~

In action.
knoba - lab tripod

~§~

CAD file link below.
knoba - lab tripod

~§~

knoba – lab tripod – 2017.dxf

•••

Usb magnifier

Great bit of kit, bought from Ebay, but plastic lens was very poor.
knoba - usb magnifier

~§~

Lens taken from broken camera, ground diameter with diamond disk.
knoba - usb magnifier

~§~

Maplin drill converted cable entry to 2.5dc connector.
knoba - usb magnifier

~§~

Optic holding flange (white plastic); increased the depth to suit new lens with diamond disk.
knoba - usb magnifier

~§~

My “goto” tool for component markings.
knoba - usb magnifier

~§~

knoba - usb magnifier

•••