I was looking at a leftover translucent case that I had just finished laser-cutting, and I realized that I could still use some of the scraps. This instructable will show you a way you can make free (good) washers out of spare Polypropyline cases for DVD's, CD's or the old Zip Disks.
(This instructable fulfills the expectation for our Bare Paint meetup on May 21st, at the Omaha Maker Group.)
Step 1: Step 1, Drill Holes to Size
Using a drill press to ensure you don't crack the plastic (which makes any washer useless), Drill holes in a straight line if possible, and as close to equidistant as possible. The plastic here I am using necessitates that I scatter the holes out more than I would like. The blue case on the right is a better example of what to do.
Step 2: Step 2, Cut the Holes Out in Strips, If Possible.
Using a nice shear made by IKEA, I was able to easilly cut the Polypropyline out into strips of plastic with holes in them. I then cut out the individual washers, while holding the strip of plastic lengthwise between thumb and forefinger. Lots of cheap washers!
Step 3: Step 3, That Extra Mile!
If you don't like the "Square" washer look, you can either put on the bolt and trim to the size of the head or you may do the following: Put all the washers on a bolt, go to a belt sander and sand until they become well rounded. To get a good result, make certain that each square washer is exactly the same dimension, and you will end up with a perfectly rounded washer that is consistent with the others on the spindle.