Instructables
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. 
 
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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.

Matherials
  • #8 woodscrew 1 inch in length
  • 2 inch finish nail
  • Aerosol paint
Tools
  • 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
100_3414.jpg
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.
caarntedd1 year 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)  caarntedd1 year ago
Thank you.
skrieger1 year 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)  skrieger1 year 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)  Creativeman1 year 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.
stroland1 year ago
It looks great Phil. A lo of work but that is the job you signed up for...pleasing your wife.
Phil B (author)  stroland1 year 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."
rimar20001 year ago
Good work, Phil, as always.
Phil B (author)  rimar20001 year ago
Thank you, Osvaldo.
WWC1 year 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)  WWC1 year 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.
iceng1 year ago
Very well done !
Phil B (author)  iceng1 year ago
Thank you. Maybe someone else will need to do this sometime.