Retro auto tool cabinets

Both cabinets made from recycled stuffs.

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Slotted angle and Dexion for the framework.

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An assortment of car badges collected over the years.

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Each cabinet is 1’x1’x3′ (300mm x 300mm x 915mm).

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This perspex had been hanging about for decades, finally found a spot.

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The wood is pine & machined from an old packing crate.

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The backs are from some old 5 gallon oil cans.

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I sprayed the shelves.

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Used for storing retro auto tooling.

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Materials (per unit):
2 x 1'x3' shelving sheets
2 x 1'x1' side shelving sheets
4 x 1"x2"x3' unequal slotted angle
4 x 1"x2"x1'unequal slotted angle
2 x 1'x1/4"x19" polycarbonate sheet
1 x 5gal oil drum skin
2 x 1 1/2"x1"x3' soft wood
Danish oil
6 x 8x1" countersunk woodscrews
8 x 1/4"x1" nuts, bolts & washers
Paint
Selection of badges
Strong double sided tape

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Dexion – Slotted angle

3m – Super strong double sided attachment tape

Paints4trade – Direct To Metal Paint

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Fid

Made from well seasoned beech wood, danish oil finish.

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Used for leaded windows & stained glass work

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Wood-database.com – European Beech

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Woodwork awl

Recycled from a well-worn & much favoured Stanley philips 201 screwdriver. Re-ground & oil stone honed with 4 sided point

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Awesome as a point awl (marking accurate; screw / drill points with brad point bits, flat bits & forstners)

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Stanley – hand tools

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Tool rings

Quick release rings for the tools on my electronics bench

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Made from the sprung stainless steel inserts from old car wiper blades (the rubber bit sometimes has these in it, ask at your local garage) & some 2.4mm stainless wire for the jump rings.

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Shaped with jewellery pliers

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Better than keyring style rings, these quickly lock into, and out of, place

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Materials:
1 x auto wiper blade insert (normally 2 in each rubber blade)
1 x 40x2.4 mm o/d stainless steel wire

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Metalwork mallets

large diameter heads & long reach heads in double wedge, round & flat

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Heads are home grown & seasoned holly, wedges are mahogany & handles are beech.

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

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Added extra weight with heated and shrunk rings

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3 smaller mallets, beech dowel handles, holly heads.

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All heads danish oil soaked in poly bag, finish left on heads

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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

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Module detail, 240v ac in, 20w out

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All 8 holes drilled, cut out centre with fret saw/coping saw

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Machined with laminate trimmer (small router)

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All cleaned up. Lens (top), body (left) & module (right).

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Very slim profile, very bright.

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What’s in the CAD file…

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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

Ebay – Smart IC Driver 20W LED COB 220V

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Spool winder unwinder

Takes many sized spools

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Wire holder & hex key holder

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Adjustable friction clutch

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What’s in the CAD file…

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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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Thumb wheel jig

Jig & threaded blank

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Freshly machined thumb wheel blank

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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.

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Nice!

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What’s in the CAD file…

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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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Bobbin sander mods

Table inserts to replace the plastic ones (hole between sandpaper & table)

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Machined table inserts (made with holesaws & angle grinder), from plate

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Pickling overnight in sulphuric acid to remove mill-scale from hot-rolled steel

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

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After pickling they are desmutted with detergent & a pan scourer

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What’s in the CAD file

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Printed 1:1, they make great stick on templates for more machining

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Making a shim to fit into the aperture

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Welding magnets placed on top

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Thin bead of silicon sealer

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Drop in shim

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Drop in large table insert

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Place magnets over hole & leave for 48 hours

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Templates stuck, centre punched, pilot drilled & cleaned

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Increased hole size to 6mm (1/4″) and countersunk both sides

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Perfect. No more misaligned levels when sanding.

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Was going to install small magnets but the inserts are fine

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Added a basket for the bits & pieces.

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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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Triton tools – Bobbin sander Tsps-450

knoba – bobbin sander mods – 2018.dxf

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Steel thumbscrews & jig

What I’m making: M8 wingbolt

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Made these tabs to weld onto bolt heads (details in CAD file below)

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Replacing these plastic ones (some have broken)

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

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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)

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Countersunk 90° included angle (underside)

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Marked all & drilled (8mm) holes in uprights

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Going to plug weld (MIG) through holes to base

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Using a wingbolt tab, as a spacer, wrapped in masking tape to add some clearance

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Welded

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Dressed with angle grinder flapwheel

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Marked and sliced through only the angle iron sections

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Cleaned up

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Nuts, bevelled, threaded & marked. From hex stock

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90° included angle

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Different threaded nuts

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Nuts hold the bolts in good contact & alignment

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Tabs are centre marked, drop in with good alignment, ready for welding

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What’s in the CAD file

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knoba – steel thumbscrews & jig – 2018.dxf

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Spot weld tip shaper

Machined from 22mm o/d silver steel. Top side.

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Underside.

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Dremeled with diamond burrs.

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Held at cherry for 6 to 7 mins.

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The gauze, I was trialling, was only good for tempering.

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Quenched, here.

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Made to fit a thread die holder.

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Finished piece. Can be sharpened on either side of cutting edge.

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Link to CAD file below.

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knoba – spot weld tip shaper – 2018.dxf

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Tool tang drill bit

Almost any steel will do. 7mm o/d, 2 straight flutes, 1/4″ increment depth marks

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Used in lathe, with new handles. Enlarge to fit individuals tangs…

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4° included taper (as per machine taper)

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Can easily remove shank for re-tempering. Link to CAD file below

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Wiki – Machine taper

knoba – Tool Tang Drill Bit – 2017.dxf

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Jewellers bench plate

Plate is 5mm x 200mm, spot welded clamp bracket is 2.2mm, mild steel.

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Clamp is 6mm x 25mm, m8 threaded bar, turned piece on end

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Finish is sulphuric acid pickling & satin black cellulose

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Good stability, very solid.

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knoba – Jewellers Bench – 2016.dxf (CAD file link below)

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knoba – Jewellers Bench – 2016.dxf

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Bumping file

Bumping file for car bodywork, made from old straight file

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Double ended with reversible “plasti-dip” handle.

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Smoothed section in centre for index finger.

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Plasti-dip – Specialty coatings

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Nogging master for arched wood roofs

Component parts overview…

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2″ by 2″ softwood, M8 coachbolts.

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Assembled.

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Folds up.

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Machined a nice thumb nut for it from aluminium.

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Nogging master measuring dwang geometry…

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Place on timber (3″ x 2″ here), mark & cut!

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Notes.
• Perlins can be continuous or split form.
• Saves time.
• Eliminates waste, cost & mistakes.
• Inexpensive & easy to make.

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*** Mk2 incorporates the “Plate Pilot” for accurate ‘birds mouths’ on the wall plate / 1st perlins nogging.

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Leather strap cutter

For cutting stiff leathers into parallel strips (belts, straps,etc.)…

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Mostly made from Iroko & stainless steel.

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knoba – Leather strap cutter – 2015.dxf (link below)

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knoba – Leather strap cutter – 2015.dxf

knoba – Adjustable Dowel Jig

Wood Database – Iroko

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Knurling copier & profiler

Single wheel knurler; mild steel, high tensile steel, stainless steel & brass.

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Filed, drilled, reamed & bevelled. Captivated dowels & countersunk bolts.

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Lever stops the sacrificial nut & bolt from elongating the body…

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Used on a tool post, near the tailstock off a live centre, profiles, formers & patterns can be made from silver steel…

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knoba – Knurling Copier & Profiler – 2015.dxf (link below)

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knoba – Knurling Copier & Profiler – 2015.dxf

West Yorkshire Steel – Silver steel.pdf

Ebay.co.uk – Stainless Steel Dowel 3x12mm

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Lathe chuck spider

Magnetic lathe chuck spider provides reference face for repeat cuts.

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Another one for my 4 jaw chuck (material is 5083 aluminium 15mm thick & 3mm x 3mm neodymium magnets).

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The spider also helps with work-holding when turning small parts.

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knoba – Lathe chuck spider – 2015.dxf (link below)

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knoba – Lathe chuck spider – 2015.dxf

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Leather Edge Bevellers

Made from medium carbon steel, brass & spalted cherry.

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Adjustable dowel & drilling jig

Used for drilling blind holes, in matched faces, for dowelling metal or wood assemblies.

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125mm x 127mm x 15mm 5083 Aluminium Plate

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Glued on cad template (link below)

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Optical centre punch (link below)

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Centre drilled used as fluffer (minimizes deflection) prior to pilot drilling

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Pilot drill all holes 3mm

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6mm drill

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Cut out profile

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Filed. A good selection of files helps; the dreadnought type is especially good on aluminium.

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Cleaned up a little more

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…and a little more

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Homemade edge chamferer/deburrer from an old three square file

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Drilling ready for threading m12 inserts

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Threading

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Countersinking

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Inserts: centre drilling

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Countersinking a relief to stop the slot in the screw snaping the twist drill used in the next operation

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Drilling to finish size

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Stamping sizes on the heads (there are 5 different sized inserts in my set)…

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Inserts fit nice…

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Insert needs to be below the surface on both sides

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Main body finished & inserts finished.

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Marking out the fences for the tool

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Cutting the parts

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Drilled, tapped,assembled to slider blocks and lapped flat

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Wallop….

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Underside

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knoba – Adjustable Dowel Jig – 2015.dxf (link below)

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knoba – Adjustable Dowel Jig – 2015.dxf

knoba – Optical centre punch

knoba – Dewalt chop saw mods

Wiki – 5083 aluminium alloy

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Optical centre punch

View of the CAD file & assembled materials (brass, medium carbon steel & acrylic)…

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All machined to stated dimensions.

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Loupes’ internal bore has been reamed.

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Polished rings at ends and grained through body for finish & finger grip.

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Recess for rubber ‘o-ring’ to stop the loupe slipping out of position.

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Centre punch is being soaked (the punch is at the front & the bits at the back are for another project).

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Punch is going to be quenched in old engine oil.

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View through loupes’ optic.

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CAD drawing below is for another project and the reason I wanted to make this tool.

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O-ring fitted and held in place with epoxy glue.

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Tool needs a case to protect the optic and keep the tool together.

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Looking forward to using it for the next project…

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Cross-hairs were scored on the lathe and highlighted with a blue sharpie pen.

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knoba – Optical Centre Punch – 2015.dxf (link below)

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knoba – Optical Centre Punch – 2015.dxf (updated)

With thanks to “PJ’s” at PJ’s – Home

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Leather Burnisher

In Iroko & brass, with polished waxed finish…

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Colron – Refined Finishing Wax

The wood database – Iroko

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Small wood plane

Luthiers wood plane.

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Body & wedge made from English oak, pin from Rosewood, blade from high carbon steel.

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Wood Database – English Oak

Wood Database – East Indian Rosewood

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Machinery dust covers

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Covers made from Polyester Cotton. Properties: strong, durable, breathable, good wear resistance, washable, dries quickly, moisture absorbing, light weight, inexpensive, easy to sew.

Hems are weighted with stainless steel ball chain.

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Sewessential.co.uk – Polyester Cotton Material

Ebay – Ball chain

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Woodwork clamping blocks

4″ x 4″ x 2″ softwood. Non-marking, large surface area with 1/8″ edge over-round.

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Waxed for an easy glueing release agent.

Better to be made before one needs them!

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Colron – Refined Finishing Wax

Freud – 1/8″ Radius rounding over bit

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Blocking tools for style lines

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Vehicle bodywork: sanding style lines.

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Accurate profiling was obtained by inverting abrasive sheet on good sections of bodywork & working the tools to shape.

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Made from softwood. Retainer bars made from stainless steel.

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knoba – Ford transit mk5 motorhome

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Invest in yourself!

Router Bases

Machined from 6mm clear polycarbonate sheet.

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Dewalt – 1/4″ DW621K Router

Dewalt – 1/2″ DW626 Router

Freud – FT2020 Template Guide Kit

Wiki – Polycarbonate

Homemadetools.net

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Tig filler rod dispensers

Made from 50mm x 3m Waste pipe & 50mm Socket plugs.

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TIG trolley was specifically designed to use these tubes.

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BES – Water Waste Solvent Weld Pipe & Fittings

knoba – TIG trolley

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Leather wallets for rasps

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Cromwell – Bastard rasp

Cromwell – Saftey wooden file handle

Ebay – 15mm snap fastener

Pfaff – select 3.0 sewing machine

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Tap & die box

Made from mahogany and aluminium angle.

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Lettering done by overstamping on a paper printout.

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knoba – Tap & Die Box – 2009.dxf (link below)

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OSG – Taps & dies

knoba – Tap & Die Box – 2009.dxf

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Planer / thicknesser blade honing jig

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Oak.

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one-hand temporary earthed bench power outlet

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Hooks over the desk/bench edge.

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Made out of an old ATX computer case…

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Ends were shaped over a wooden buck/form

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ilovefreegle.org – Free stuff & community recycling

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computer

Plumb bob

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knoba – Metal casting furnace

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Wood turning fixture & rests

Lathe wood turning fixture & polished 304 stainless steel rests

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Extended rest.

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knoba – Radius keepers

knoba – Spur drive

Homemadetools.net

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