Picture of Custom Screw Eyes
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. 
Remove these adsRemove these ads by Signing Up

Step 1: Tools and Materials

Picture of 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
  • Aerosol paint
  • Vise
  • Slip-joint plier
  • Steel rod equal in diameter to the eye opening
  • Dremel tool with cut off wheel and grinder stone
  • Hammer
  • Wire feed welder
  • Spring clamps
  • Sheet metal for a shim

Step 2: Bend the finish nail

Picture of 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

Picture of 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

Picture of Cut the screw
Use a Dremel tool with a cutting wheel to remove the head from the woodscrew.
caarntedd2 years ago
Nice work Phil. I too have, on MANY occasions gone to the hardware store only to find something close to what I need, but not exactly. Either that or they have run out of the item I need and I've had to make something with the available alternatives, or some junk I've had on hand. Your screw eyes also look quite rustic. Nice.
Phil B (author)  caarntedd2 years ago
Thank you.
skrieger2 years ago
This is a great idea. How many times have I gone to the store just for for the screw eye when I was sitting on top of the welder DAaaaa I have made many T handles with bolt. Great job
Phil B (author)  skrieger2 years ago
Thank you. Worse yet is going to the hardware store and finding things which almost do what is needed, but not really. As I mentioned, I went for most of my life without a welder. During those years I sometimes managed to braze things like this with a MAPP gas torch. But, if you have access to a welder, getting what you need from what you have becomes easy. Thank you for looking.
Good idea, phil! I'm welder challenged however. I just go to my can in the shop that is labeled "for your eyes, only!"
Phil B (author)  Creativeman2 years ago
Clever. Have you ever looked into a MAPP gas torch? They are more expensive than a similar common propane torch, but allow you to join small metal parts with braze. Thanks for looking.
stroland2 years ago
It looks great Phil. A lo of work but that is the job you signed up for...pleasing your wife.
Phil B (author)  stroland2 years ago
You are a man in whom wisdom resides. The work required went pretty quickly, especially on the second one after the tutelage gained from the first one. If "10" were a huge amount of work and "1" were no work at all, I would give this about a "4" or a "5."
rimar20002 years ago
Good work, Phil, as always.
Phil B (author)  rimar20002 years ago
Thank you, Osvaldo.
WWC2 years ago
Nice job.
I have made different versions of this from time to time but i tend to deem it finished soon as it is usable
Unlike yours where it is ground down and painted.
Phil B (author)  WWC2 years ago
Thank you. I figured I would not be the only one to have thought of this. I am like you. A rough finish is usually good enough, if it does the job well enough. But, my wife has different standards from my own.
iceng2 years ago
Very well done !
Phil B (author)  iceng2 years ago
Thank you. Maybe someone else will need to do this sometime.