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How to make your own permalok needles

How to make your own permalok needles
Those of you messing around with paracord probably know what these are already.
If you don't, they're basically large diameter needles that thread from the back, parallel to the needle body, so they don't create extra thickness from threading them on large diameter stuff ( paracord, leather...).

Although not essential, they can make your knot related work much easier and enjoyable.
I thought these needles were gadgets, and have always been able to make all my fancy knots without such tools.
But I must admit that since I began using my first homemade needle, the hobby went even more enjoyable than it was before,
give 'em a try !


My problem is that where I leave ( France ) these are impossible to come by.
Buying them online was the obvious alternative I've considered for some time, but I would end up paying three times as much in shipping costs than I would for an actual set of these.
So this is where DIY kicks in.

There's nothing really complex about these, and if you have a slightly equipped shop, it should only be a matter of minutes. ( My first try probably took me 20-30 min, half the time being spent looking for the right tools.

But since I wasn't able to find any resource online concernig making them yourself, I decided I might just publish my own attempt at it so others could benefit from it.
( Actually I've found some instructions on making lacing needles by hammering and filing brass pipes, but did'nt like their aspect at all.Also, it limited sizing options too much for me .)

These are easy, cheap, and work awesomely well !
What are you waiting for ?

Oh, and there are also a couple other advantages in making them yourself:

- You can quickly make a new one for most sizes of cord, string or anything.
- You can make them the shape, the length, the size, and nose form you need.
- This includes curved ones for works on coverings etc...

I will be covering the making of a needle designed to fit standard 550 paracord in this Instructable.

Have fun !
 

 
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Step 1What you will need

What you will need
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Here are the few tools you will need to do this.
You might get away with less tools and more ingenuity, but this is the "basic" toolset that will make the whole process a breeze.

- One brass rod , ( For 550 paracord, I used a 6mm rod, which seems to be just perfect )
- A drill press ( This might be the hardest to source for some of you, but it will allow you to drill a nice straight hole down the rod easyly.)
- A dremel tool for the cutting/finishing of the needle.
- Various cutting, grinding and polishing bits.
- A set of threading taps matching the diameter of your rod. For paracord and a 6mm rod, I used 4X0.70 mm taps. 
- A drill bit, choose it accordingly to the kind of tap you're using. I used a 3.2 mm bit. It should have been 3.3, but that's close enough.
- Optionnally, a bench grinder

That's it !

If you choose alternative ways of construction, you might also find usefull to have:
- a hack saw 
- sand paper
- a lathe ( this would surpass the whole drill press thing on any aspect, but most of you won't have the privilege of owning one, so I will describe the "poor man's" drill press way here, as they are way more common )

Once again, this is only one way of doing it.
Depending on your tools or skills you might find many more.
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20 comments
Jan 23, 2012. 6:40 PMLextone says:
Great Ible. Gotta try that technique for drilling rod....but its not a good Idea to use a bench grinder for Brass (or aluminum, wood or any malleable metals for that matter). Being soft it will clog the pores on the face of the wheel. This can cause over heating and the wheel can have a catastrophic failure causing injury.

You can however use a file and your drill press to form the tip just as you would do on a lathe. Just be sure to use a wooden handle....or you may wind up in the emergency room. (The pic below is a friend of mine who didnt do that)

Be careful and apply common sense!

Jan 26, 2012. 12:05 AMcurious youth says:
ouch. did he lose any mobility ?
Jan 26, 2012. 12:25 PMLextone says:
Luckily no. It mostly went through the fatty tissue of his hand. No nerve or muscle injury. His First Aid training kicked in when it happened and he fought his initial reaction to pull it out. Having it removed at the Hospital more than likely saved him from any further damage. In this pic he is all jacked up on pain killers in the Hospital waiting on the Doctor to come.
Jan 26, 2012. 3:30 PMcurious youth says:
Wow. such a lucky guy and lucky he knew first aid. i know from mine that if he pulled it out it would be much much worse. Everytime i look at the picture im feeling a massive throb in my hand.
Jan 7, 2012. 9:22 PMMadBricoleur says:
Wowow, that is a great idea for center drilling small diameter rods. I'd have never thought of that. Thanks so much!!
Dec 19, 2011. 8:26 PMsolomonhorses says:
AWESOME! I love the upside down drill bit trick! Keep up the good work!
Aug 21, 2011. 2:05 PMRobotic_mage says:
Great Instructable. I but knitting needles, which are hollow aluminum, cut to size, then just a quick threading with a tap. I can usually find a pair of needles for $0.50.

Paul
Dec 9, 2011. 4:40 PMaristide202 says:
you'are great !
Nov 8, 2011. 11:48 AMAaronius says:
Brilliant!
Oct 8, 2011. 3:48 AMmicraman says:
Great stuff! shoulda made one of these ages ago :D
I was thinking, since I don't have a drill press, maybe i'll get a brass tube and tap both ends. One end for the paracord, the other for the tip.
For the the tip I'll just shape it somehow (with lots of elbow grease!) and then put it in a die to make a threaded end.
This would allow me to change tips too! Whadya think?
Sep 17, 2011. 2:48 AMtech_monkee says:
I love this instructable.

on a side note for some that might want a thinner needle:

a few years ago i bought some "portable" stainless steel chopsticks online for like $5.00 usd shipped. these chopsticks unscrew from each other. the pointed end being the part where the paracord would screw into. i used these to make a few cases for my phone and it was very easy to thread with.

that said - i will be making some of those fatter diameter ones to have more options :)

thanks for the instructable.
Aug 23, 2011. 11:11 AMzazenergy says:
Great instructable, very thorough instructions. Thanks!
Aug 21, 2011. 7:09 PMrimar2000 says:
Very interesting. I like specially the step 4.
Aug 23, 2011. 9:17 AMThat One Eegit says:
Yes, step 4 is very creative.
Aug 22, 2011. 4:58 PMmblack3 says:
Excellent! I have wanted to do this for a while and your instructable helped immensely!
Aug 22, 2011. 9:13 AMdiyoutdoorsman says:
Your needle is also called a fid. You can find them in various hardware stores and boating/maritime suppliers. I noticed a couple of different sized plastic ones in my local hardware store the other day.
Aug 22, 2011. 4:31 PMrichie_114 says:
Read yours right after posting mine, Man.. I hate reposting something someone else said.... Sorry!
Aug 22, 2011. 4:30 PMrichie_114 says:
Ohhhh.... I was trying to figure out what a "permalock needle" was, I think I remember them being referred to as a "fid" basically a hollow needle you weave ropes with (not just hollow braid either)
Aug 22, 2011. 9:23 AMCementTruck says:
Really good idea! Great follow through.

I was struggling with an idea on how to make my own Permalok needle a few months ago. I dug through my Box-O-Stuff where I toss things that might come in handy in the future and came across some proprietary IBM cable male/female gender benders. They had stainless steel screws that held 2 cables together. I cut the thumbscrew off the female screw and sharpened the tip. it works fine, but is a little short. I like your idea much better.

Kudos.
Aug 21, 2011. 3:07 PMcraftydan says:
Nicely done -- a thorough instructable with a few good fabbing tricks.

There is a (IMO) simpler procedure over at KHWW (but when was simpler better for a weekend project?).  Involves small gauge copper tubing, a self tapping screw, a hammer and some finishing supplies.  It's little less machine intense, but I've got a feeling yours is a bit sturdier.



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