Step 1: Materials
6" of 3/8" x 2" steel bar stock
x4 - 2" of brass round stock
x2 - 4"x2" of thin aluminum sheet
either some spring stock or scavanged spring
wood 4"x2" (I used oak, teak and mohogony)
scrap brass, copper or aluminum sheet (decorative)
Two part epoxy
wood glue (if needed)
wood oil or stain and clearcoat
drill or drill press
a whole lot of time and patients! this project took me over 30 hours!
(lots of stuff to learn)
Step 2: Planning, cutting and shaping
You can use cardboard to make a mock setup of the opener, me, I just jumped right in and rough drew on the metal. Having no access to a ban saw that will cut metal I had to drill the out line and hacksaw the rest. Hopefully you have access to a band saw as this task is grueling. The hardest part will be shaping the mouth of the opener; I drilled two holes and then got busy with a thin rasp and jewelers files. As a side note, it is wise to file teeth grooves into the part that grips the lip of the bottle cap (so it does not slip). At this point to can clean up the edges with either a file, grinder or belt sander.
Step 3: Gluing and more drilling, fitting
Fitting the locking lever to the opener is a real task, take your time, I hand filled this entire step.
Take the locking lever and the opener and place it so it fits on the wood/aluminum grip mark where the holes should be drilled and drill the wood and steel with the drill press. get the other wood/aluminum grip and match it flush with the other grip and use the already drilled holes ad pilot holes and drill the other one out (plugging the holed with the brass round stock as you go).
Now you can put everything together and test how it works, make adjustments as needed.
Also it would be a great idea to polish the steel a little and remove any tooling marks!
Step 4: Adding decoration and shaping the wood
As seen in pictured two, three and four I added bits of brass and aluminum (did not use copper). The idea for this came about when I got over zealous with my filing of the locking lever and opener engagement. I needed to fill in some area so I made it decorative and functional! I epoxied 2 brass caps on the lever and cut 3 slots in the lever (not too deep) and filled those with one brass and two aluminum scraps.
Step 5: Rounding the profile and epoxy
Mix the epoxy and apply with caution! Clamp down base area, then test to make sure it is functioning properly and not sticking!
Step 6: Finish shaping and apply coat
Using a belt sander and sand by hand to get that nice round shape on the grips, then apply linseed oil or stain/clearcoat to finish.
Then polish up the steel to a good mirror finish (or close)
now crack open a fine brew and enjoy the best opener you will ever have!
Step 7: Final thoughts
1. Make the locking lever a little thinner - it was just a little too thick but still functions fine.
2. Drilled the holes more inward on the grips - they are just to close to the edge in my opinion.
3. Polished the inside of the opener - left it rough inside, no big deal though.
4. The wood - I think just teak and oak would have looked better.
Thanks for looking! This is my first instructable, I hope you guys enjoy it and stay tuned for more!!
here are a few othe openers I made in the pictures. more instructables to come for atleast one of those!
Step 8: If i win...
Being an engineer tech I am very familiar with AutoCAD, I use it every day. In my spare time I have also learned Google sketch up as well. I think this would take my design and building skills to the next level.
Also, thank you for featuring my first project!