For $#!%s and Giggles
-A type 1 Lever
Sheet Metal cut to 2 1/2'' x 3 3/4"
End Mills (1/16"-3/16" & 3/8")
Bench Grinders/Angle Grinder (to shape and polish)
Ariteeee let's get started!
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Step 1: Measure!
Basically a 2 1/4" x 3/4" Box
With a 1/8" inward extruding lip 1/2" wide
Darkened out the negative for easier milling purposes
Step 2: Prep the Mill
The smallest End Mill available at the time was 3/16".
If you can get a 1/16" go for it, whatever works for you.
Support the middle of the Work with pieces of wood between your Parallel Bars
Step 3: Na-na-na-na-na-na-MILL TIME!
I started from the Top Left and worked my way around.
Remember to use lots of Cutting Fluid!
Step 4: Flatten & Shape!
I chose a digivice-esque shape
Mark it off and cut with TechShop's handy Metal Shear.
Step 5: DRILL Dat HOLE
Mark off where you want the hole.
(I went back and made the Work a bit thinner, adjust accordingly)
Step 6: File & Finish
Smooth out the insides/edges
Step 7: Ta-Da!
Now go and open a refreshing cold one ;)