Introduction: How to Make Steel Knuckles
Disclaimer : These are not a toy, and this isn't a mockup made of out of harmless materials, These are dangerous and nasty and I would hope after the fabrication of these you behave rationally. Steel is dense, bone is brittle. That being said lets begin. Im aware that one method of cutting,drilling or finishing metal might not be available too you so i attempt too offer alternative methods for fabrication. Please excuse the poor images im no photographer.
Bill Of Materials :
1. 1ft long by 4in wide by 1/4in thick plate steel.
2. 1in diamter bi-metal hole saw
3. A way to weld, or you could use 1/2in thick (much harder too cut ) or simply leave them 1/4in thick.
4.A way too cut metal ex. metal cutting jigsaw,sawsall or hacksaw(for those of you with real gumption :) personally i'll be using a bandsaw with a 24 TPI blade.
5. Metal center punch and hammer for marking center points in the plate steel.
6. 3/4inch drum sander with 80 grit sandpaper
7. scribe,sharpie or pencil(hardest too see,wouldn't advise it ) if a scribe is used get one where the tip i made out of tungsten so it wont round over on the mild steel.
8.A ruler that can measure in millimeters if you dont want too purchase one you can download one at www.boltdepot.com
9.Square or straight edge
10. posterboard, cardboard or computer paper for the template
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Step 1: Steel Preparation
When you purchase steel from your local hardware its coated in zinc oxide too protect it from corrosion that might occur on the shelf. Use your 80 grit sander too remove this coating until you are left with bare steel. If you are gonna draw the silouhette of the knuckles on with a sharpie i would wipe it down first with rubbing alcohol or minerals spirits.
Step 2: The Template
Use a 1" bi-metal hole saw too punch out finger holes and the two outside are parallel and the 2 center holes are paralell but higher than the other two by about an 1/4". After you mark out the holes draw the material outside the finger holes and the grip.
Step 3: Marking Drill Points and Cutting the Profile
Now with your template cut out and the center points all marked out secure the template by taping it too the steel. Use your punch too mark the center points and where it will curve inwards. Drill the smaller diameter holes first, then onto the 1in holes. Remember: When drilling steel keep your drill at a very slow speed, too fast and you will anneal the cutting edge of the bit or saw and render it useless. Now on too cutting the profile. Cut just outside your line too allow for sanding and filing too the final shape. If you are doing like me you have too cut two out of 1/4in plate.
Step 4: Deburring and Filing
Unless you cut it out perfect take this is your opportunity too debur the fingerholes and shape the areas with a file that didn't come out right.
Step 5: Plug(Rosette)welding
*If you cut your knuckles from one plate than this step does not apply too you.
This step I could not photograph because all you would see is a ball of light in the photo.
Here's the gist of whats happening though, you are using molten steel as a fastener between two pieces of steel. When you are doing this dont tack weld or stop. Dont worry about overfilling the weld you should sand it down with 120 grit after you are done.
Step 6: Polishing
At this point if both of the plates are not perfectly lined up you can shape them with the 80 grit till they are flush together. After you have shaped them sand them down with 120 grit then polish them with #4 and #1 abrasive wax polish with a cotton wheel. #4 is black and #1 is green spend it about 3 million hours polishing them and they look like this
Step 7: Now Its Over
Have fun but be responsible. If you want a good finishing tip head to caswellplating.com the last portion of this project was going too be me electroplating the steel with brass but i ran out of money. If any of you cyber punks get your hands on a brass plating wand and do this forward me photos i would love too see what one would look like with a brass coat.