Metalwork mallets

large diameter heads & long reach heads in double wedge, round & flat
knoba - metalwork mallets

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Heads are home grown & seasoned holly, wedges are mahogany & handles are beech.
knoba - metalwork mallets

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Handles turned from old table legs, spoke shaved ovoid, danish oiled and burnished smooth with 00 wire wool.
knoba - metalwork mallets

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Added extra weight with heated and shrunk rings
knoba - metalwork mallets

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3 smaller mallets, beech dowel handles, holly heads.
knoba - metalwork mallets

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All heads danish oil soaked in poly bag, finish left on heads
knoba - metalwork mallets

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knoba - metalwork mallets

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knoba - metalwork mallets

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Materials:
Large heads: 2 x 125x50 mm o/d (5"x2" o/d) holly
Long reach heads: 2 x 180x40 mm o/d (7"x1 1/2" o/d) holly
Small heads: 3 x 100x32 mm o/d (4"x1 1/4" o/d) holly
Large head handles: 2 x 280x40 mm o/d (11"x1 1/2" o/d) beech
Long reach head handles: 2 x 325x40 mm o/d (12 1/4"x1 1/2" o/d) beech
Small head handles: 3 x 330x15 mm o/d (13"x19/32" o/d) beech
Danish oil
00 Wire wool

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Wood-database.com – holly & beech/

Colron – refined danish oil

Liberon – steel wool

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Tool throat LED

CAD stick-on templates, polycarbonate sheet & LED module
knoba - tool throat LED

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Module detail, 240v ac in, 20w out
knoba - tool throat LED

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All 8 holes drilled, cut out centre with fret saw/coping saw
knoba - tool throat LED

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Machined with laminate trimmer (small router)
knoba - tool throat LED

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All cleaned up. Lens (top), body (left) & module (right).
knoba - tool throat LED

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Very slim profile, very bright.
knoba - tool throat LED

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knoba - tool throat LED

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What’s in the CAD file…
knoba - tool throat LED

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Materials:
1 x 75x50x10 mm (3"x2"x3/8") polycarbonate sheet
1 x 75x50x3 mm (3"x2"x1/8") polycarbonate sheet
4 x M3x20 mm (1/8"x3/4") pan head machine screws
2 x lengths 7/0.2mm insulted wire (to suit connection distance)
1 x length heat shrink (to suit connection distance)
1 x small cable tie

nb. plastic sheet was recycled from computer monitor diffusers

Note: 1Amp in line fuse on live side. Use dpdt if switched.

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knoba – Tool throat LED – 2018.dxf

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Spool winder unwinder

Takes many sized spools
knoba - spool winder unwinder

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knoba - spool winder unwinder

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knoba - spool winder unwinder

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Wire holder & hex key holder
knoba - spool winder unwinder

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Adjustable friction clutch
knoba - spool winder unwinder

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What’s in the CAD file…
knoba - spool winder unwinder

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Materials:
1 x 142x100x6 mm (5 5/8"x4"x1/4") plate/sheet mild steel
2 x 50x80x3 mm (2"x3 1/8"x1/8") plate/sheet mild steel
4 x m5x12 mm (3/16"x1/2") socket head bzp machine screws
4 x 12mm (1/2") o/d rubber stick on feet
2 x 25x30 mm (1"x1 1/4") nylon 6-6
3 x M6 (1/4") stainless steel penny washers
1 x M6 (1/4") felt, penny washer size
1 x M6 (1/4") conical spring
1 x M6 (1/4") thumb wheel
2 x M4 (3/16") grub screws
1 x M6 (1/4") circlip, or e-clip, or any other axial load shaft retainer
1 x 250x6 mm (10"x1/4") stainless steel bar
Some paint
& a handle (wood, metal, I used beads for jewellery)

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knoba – spool winder unwinder – 2018.dxf

knoba – thunb wheel jig

Rapid electronics – stick on rubber feet

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Via punches

Machined punches for brass through hole rivets
knoba - via punches

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Copper tracks had lifted, component had disintegrated, good repair, will use again!
knoba - via punches

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Materials:
2 x 75x6 mm (3"x1/4") circular solid section stainless steel

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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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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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Lathe chip guard

Guard stops hot chips burning my feed hand
knoba - lathe chip guard

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Made from take-away containers
knoba - lathe chip guard

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Flexible, see-through, long lasting, etc.
knoba - lathe chip guard

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