Step 1: Parts List for Tool
1. Description: Nut, Type Compression, Tube Size 3/4 In., Tube Outside Dia. 3/4 In., Thread Size 1-18, Thread Connection, Material of Construction Brass
Model #: G3942032
Price: $1.53 ea
2. Description: 0.375" T-304 Annealed Stainless Square Rod, Random Length (10"-12")
Model #: N/A
Price: $ 3.78 ea
3. Description: 11 x 11 x 2 R50 Carbide Insert 6.5% colbolt
Purchased: eBay Putm-Bruc seller - Drop me a note if you would like to buy some
Model #: N/A
Price: $ 4.95 ea
4. Description: 8-32 Flush Head Stainless Steal screw
Purchased: Denault Hardware
Model #: N/A
Price: $ 0.33 ea
5. Description: Wood ( Wild Almond and Iron Wood )
Model #: N/A
Price: $20 for both
6. Description: Rubber Washer 9.5 x 17.5 x 4 mm
Model #: N/A
Price: $3.99 set
Step 2: Tools That I Used for This Project, These Can Be Replaced by Others.
Photos 2-3: Powermatic (1971) Bandsaw - Craigslist
Photo 4: 12" Ridgid Miter saw - Home Depot
Photo 5: Shop fox Drill Press - Amazon
Photo 6: Jet 12" Disc Sander - Woodcraft
Photo 7: Jet parallel Clamp 12" or larger - Woodcraft
Photo 8: Files.. Course, Medium and Fine - Woodcraft
Photo 9: Countersink with tool to apply it - Woodcraft
Photo 10: Tap Handel with 8-32 tap - Lowes
Photo 11: Grinder - Sears
Photo 12: Metal vice and hand held disc grinder - Harbor Freight
Photo 13: 3/8" Chisel - Woodcraft
Photo 14: Plastic Mallet - Woodcraft
Photo 15: Wire wheel - Home Depot
Photo 16: Lathe Caliper - Woodcraft
Photo 17: Large adjustable Wrench 1 1/2" Capacity - Lowes
Photo 18: 2 Jorgensen Clamps - Woodcraft
Photo 19: Gorilla Glue - Woodcraft
Photo 20: Tap Magic - Anazon
Photo 21: Medium CA Glue - Woodcraft
Photo 22: Thin CA Glue - Woodcraft
Photo 23: EEE Ultra Shine - Woodcraft
Photo 24: Gloves and scissors - Lowes
Photo 25: Wax paper - Vons
Photo 26: Tape Measure - Woodcraft
Photo 27: 6 inch scale - Woodcraft
Step 3: Cutting Wood to Size
Step 4: Gluing the Wood Together
This requires wetting the surfaces with water befor gluing..
I use parallel clamps to assure the parts stay square to one another and place wax paper on the clamp where the glue joint is to eliminate the need to scrape glue off the clamp
Step 5: Prepping the 3/8" X 3/8" Stainless Bar
As you can see from the photo, mine were cut to 11 inches.
As the ends we're rough cut, I used a file to smooth them.
Step 6: Drilling - Learning - Drilling
I started out drilling the holes for a 6-32 tap.. what I found is 304 SS work hardens fairly easily.
I read that when you drill SS you need keep the speed slow, 200 - 300 RPM, and use cooling fluid, oil and press hard.
You drill wood at approx. 1500 RPM's and you don't drive the drill by pressing too hard, plus you pull the bit out frequently to remove wood chips.
When I drilled the 6-32 tap hole I drilled through the material too slow. The good news it just work hardens in a local area, so drilling out for an 8-32 tap I drilled through quickly while sucking air over the metal with a shop vacuum.
Photos 1-8 are drilling the SS for a 6-32 tap
Photo 9 is a broken 6-32 tap
Photos 10-12 are drilling the SS for a 8-32 tap
Step 7: Tapping the SS Bar With a 8-32 Tap
I used tap magic on the tap and assured I removed metal chips as I cut.
Step 8: Marking and Grinding to Place the Carbide Insert Flush With the Top of the SS
Photos 8-9 show clamping a piece of maple to the SS to Grind it.. This did 2 things, one it produced a stop for Grinding and two allows me to hold the SS as it gets very hot.
Photos 10-12 show Grinding
Photos 13-17 show the ground SS before it is filed.
Photos 18-19 show the final cut, that has been filed and fitted with a carbide insert.
Step 9: Cutting the SS to Length
I used a hand grinder and a vice to cut each piece to 9"
I then ground the end I cut in a bench grinder.
Step 10: Trimming the Glued Wood
Photos 3-7 show the trimming of the corners and results
Step 11: Marking the Centers, Tapping in the Spur Center and Mounting to the Lathe
Photo 2 shows the spur center tapped in with a hammer. You can also make your X and then cut it on the bandsaw.
Photos 3-4 show the spindle mounted on the Lathe
Step 12: Measuring the Compression Nut Diameter and Depth and Marking on the Spindle, Turning for the Nut to Be Threaded On.
Photos 2-3 I mark the depth on the spindle where I turned it round on the end.
Photo 4 turning the spindle to diameter
Photo 5 checking with a caliper
Photos 6-7 I used a large adjustable wrench to thread the brass compression nut on the wood spindle.
Step 13: Using a Course, Medium and Fine File on the Brass Fitting
Once it is round, I use a med. then fine file to smooth and polish the brass.
Note that I have dust collection hose just under the brass compression nut to remove the brass dust while filing.
Step 14: Finish Turning the Spindle and Applying CA Glue for the Finish. Polishing With EEE Ultra Shine
Photos 1-5 show turning the spindle
Photos 6-8 show the spindle with CA glue.. To understand how to apply CA glue, refer to my instructable on making a pen.
Once the CA is applied and sanded, I use EEE UNITA shine to polish the finish.
Step 15: Drilling for the SS Bar in the Spindle, Cutting, Sanding and Finishing the Spindle End
I could have used a parting tool to remove the end of the spindle but did want to take a chance of denting the brass or wood so I cut it on my bandsaw, photo 3.
Photo 4 shows the end after cutting on the bandsaw
Photo 5 sanding on my 12" disc sander
Photo 6 ready for finish
Photos 7-8 applying thin CA on the end... as this is a bit messy photo 8 shows with cap on.
Step 16: Using a 3/8 Chisel to Square the 3/8 Drilled Hole
Step 17: Hand Grind the 304 SS to Better Fit in the Handle
Photos 3-4 shows installing the SS bar. Note that I added CA glue into the sides of the hole befor pushing and hammering in.
That last step was to slide the rubber washer over the 304 SS bar.
Step 18: Lightly Smooth the Surface of the 304 SS
Step 19: First Tool Completed.
If you are interested in buying the carbide inserts or one of the tools, please shoot me a note. I plan to auction off 3 to 4 of the tools and will be selling the inserts for the remainder of this year depending on demand.