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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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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3in1 metal working machine extras

Acquired a bare 3in1 metalwork machine (bends, cuts, rolls).
knoba - Rlc switches

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Machine needed a sturdy base.
knoba - Rlc switches

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Detail in the CAD file below
knoba - Rlc switches

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Chassis finished.
knoba - Rlc switches

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Made a shelf to catch cut sheet from perforated aluminium.
knoba - Rlc switches

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Shelf being trialled.
knoba - Rlc switches

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knoba - Rlc switches

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Machine on base.
knoba - Rlc switches

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I make tool socks for my equipment.
knoba - Rlc switches

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Elastic stitch, eyelet, nylon cord and plastic holder thing.
knoba - Rlc switches

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Keeps tooling with the machine for adjustment / maintenance.
knoba - Rlc switches

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I also make covers for my equipment. Poly cotton.
knoba - Rlc switches

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Detail in the CAD file below
knoba - Rlc switches

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Identical scales on both slip roll adjusters. Machined from ally.
knoba - Rlc switches

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Stamped & levelled thread bottoms so both top settings match.
knoba - Rlc switches

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Added a fence carrier to keep it with the machine.
knoba - Rlc switches

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Ready for work, or storage.
knoba - Rlc switches

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Materials:
1.5m x 50mm x 6mm f/s
6.0m x 50mm x 3mm shs
1m x 2mm x 12mm i/d chs
4 x castors
4 x M10 Bolts x 50mm
12 x M12 Bolts x 70mm
4 x M10 Washers
12 x M12 Washers
4 x M10 Square Weldnuts
12 x M12 Hex Weldnuts
8 x 50mm x 50mm Black Square Plastic End Caps
Paint, Direct to metal, light blue
Polycotton 2m x 1.1m
Polyester Thread
2.5m Ball chain

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knoba – 3in1 metal working machine stand – 2017.dxf

knoba – 3in1 metal working machine cover – 2017.dxf

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Van pedals

Wanted a set of 3 (not 2 + 1), legal, heavy duty, serviceable & pleasing pedals.
knoba - van pedals

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Machined from 6 series aluminium, 5mm thick, curved, hammer finished, re-machined & polished.
knoba - van pedals

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Studs are machined & polished m6 stainless button caps.
knoba - van pedals

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Van cab steps

Left; Hammer-formed finals (4mm thick, ground, beaten & polished).
Centre: Hardwood bucks routered from decking off-cuts.
Right: Original plastic steps (loading caused rust in underlying structure).
knoba - van cab steps

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No annealing required. Machined nylon66 interfaces stuck with PU sealant.
knoba - van cab steps

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Fixings are M8 stainless countersunk bolts & M8 square weldnuts.
knoba - van cab steps

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themetalstore.co.uk – aluminium 5 bar checker plate

duckduckgo.com – square weld nuts

wikipedia.org – Nylon 66

Sikaflex – EBT+ polyurethane adhesive

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Tool tang drill bit

Almost any steel will do. 7mm o/d, 2 straight flutes, 1/4″ increment depth marks
knoba - Tool tang drill bit

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Used in lathe, with new handles. Enlarge to fit individuals tangs…
knoba - Tool tang drill bit

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4° included taper (as per machine taper)
knoba - Tool tang drill bit

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Can easily remove shank for re-tempering. Link to CAD file below
knoba - Tool tang drill bit

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Wiki – Machine taper

knoba – Tool Tang Drill Bit – 2017.dxf

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Ac Power Supply

Aluminium frame pattern for recycled multitap transformer
knoba - Ac Power Supply

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Transformer core shaping buck
knoba - Ac Power Supply

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Frame made
knoba - Ac Power Supply

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knoba - Ac Power Supply

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Donor psu…
knoba - Ac Power Supply

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Ac system internals in
knoba - Ac Power Supply

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240vac @ 50Hz in: 1, 3, 6, 9 & 12vac @ 50Hz out
knoba - Ac Power Supply

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Illuminated the meter.
knoba - Ac Power Supply

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New laminated fascia (cad file below)
knoba - Ac Power Supply

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New laminated meter scale (cad file below)
knoba - Ac Power Supply

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Schematics (Fritzing file below)
knoba - Ac Power Supply

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knoba – Ac Power Supply – Fascia – 2016.dxf

knoba – Ac Power Supply – Meter Scale – 2016.dxf

knoba – Ac Power Supply – Schematic – 2016.fzz

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