My favorite tool probably has to be my drill press. It seems like any project I do involves the use of my drill press, but the joy of using it has been somewhat dampened by the fact that the vertical adjustment crank, being made of cheap plastic, broke quite easily.
I've been using this uncomfortable, hard to use crank for several years simply out of laziness., but I finally got an idea for a simple solution to fix it.
If you find this instructable useful, please vote for me in the indestructible contest! I really appreciate it!
Step 1: Find a Bike and Take It Apart!
I bought an old steel road bike a few years ago for 5 bucks. It has served me well, but I decided it was time to retire it due to the fact that new tubes and tires would cost more than the entire bike is worth.
But it is not going to waste. The first thing to be recycled is one of the crank arms. It fits almost perfectly onto the height adjustment shaft, It's made of nice tough steel, and it's shiny! Who could ask for more?
Step 2: Cut the Crank to Size!
I began by cutting the crank to be roughly the same length as the old plastic one. This stuff was stronger than I thought. I started with a hacksaw and got pretty much nowhere. It was no match for a grinder cutting wheel though. I smoothed it off and even used a wire brush to shine up the chrome a bit.
Step 3: Find a Handle!
I'm not really sure what this knob came off of, probably a roof rack or something. Anyway, I found it in my pile of hardware and I think it will do well.
I drilled an appropriate hole in the crank arm to accept this knob. When you drill through the hard metal, be sure to use a sharp bit, plenty of lubrication, and take it slow. Also, use a vise or other strong holding thing. Holding onto it by hand is a recipe for disaster. The drill press actually ripped it out of my vise and threw the crank arm across the room. Gave me quite a scare...
Step 4: Attach It!
What I did here was place a nylon washer between the nut and the arm so it spins a bit smoother. I also marked and cut the threaded rod down to size. A hacksaw was fine for this.
Remember to use loc-tite on the nut so that it doesn't come off when you spin the crank.
Step 5: Install It!
Finally, install the new crank arm onto the height adjustment shaft just like you would install it on a bike. I used the original hardware and all.
I'm very pleased with how this turned out. It doesn't look out of place and it is nice and sturdy. Quite comfortable and natural to use as well.
It stood up to being thrown by a drill press and I'm sure it will be able to last at least as long as the rest of the machine.