My wife is making a banner for a women's convention. The regulations stipulate a screw eye is to be used on each end of a large dowel crossbar. Screw eyes with a small diameter to fit the cord for hanging are light duty and the screw section is too short to be reliable. She asked if I could make two screw eyes for her.
Step 1: Tools and Materials
The photo shows a woodscrew, finish nail and nearly completed screw eye. The screw eye in the photo needs a little grinding to smooth it, yet, and it needs to be painted.
#8 woodscrew 1 inch in length
2 inch finish nail
Steel rod equal in diameter to the eye opening
Dremel tool with cut off wheel and grinder stone
Wire feed welder
Sheet metal for a shim
Step 2: Bend the finish nail
I used a screw hook 1/4 inch in diameter as a form around which to bend the finish nail. The cord for my wife's banner is 1/4 inch in diameter. A larger round form could be used to fit your needs. Rod heavier than a finish nail could also be used, if your requirements necessitated it.
The finish nail is strong enough to do the task needed, but thin enough that I could bend it by hand if I held its end with the pliers. Bend a little more than a full circle.
Step 3: Cut the finish nail
See the first photo. Cut the nail as shown by the white and yellow lines. You want the ends of the nail to meet so they form a circle without a gap and without overlapping. Pound or bend the circle so it lays flat. See the second photo.
Step 4: Cut the screw
Use a Dremel tool with a cutting wheel to remove the head from the woodscrew.