I made this paracord stylus as a tool for making a quick deploy bracelet. It's made from 1/4" aluminum bar stalk, aluminum sheeting, and an aluminum knurled screw.
It's part of my Kickstarter project. You can check it out here:
Thanks! - Brent
Step 1: Cut and Drill
I measured out about 4" and used a pipe cutter to cut the bar stock. Next I used a number 29 drill bit to drill a hole in the end about 1" deep. I used a file to remove any burs.
Step 2: Shape the Point
I adjusted the angle of my mini-lathe to 10 degrees and brought the end to a point. After that I used a file to blunt the tip and 800 grit sand paper to remove any machine marks.
Step 3: Tapping Aluminum Threads
I clamped the stylus into a vice but I made sure to protect it with a piece of leather. I then used an 8-32NC tap to cut the threads. Make sure to use a little oil to make the cutting easy.
Step 4: Cut the Clip
I used a mini-mill to cut a strip off of a plate of 14 gauge aluminum. To square the plate to the bed I used a "V" block. After I took these pictures I realized I should have put the plate in short ways since my bed only has so much travel. Another one for experience. To make up for it I just cut the last bit with some diagonal cutting pliers.
Step 5: Form the Clip
I used a file to clean up the edge. Then I used a center punch to mark the location of the hole. After drilling, I cleaned the hole with a deburring tool. Finally I formed the 90 degree bend in the vice.
Step 6: Grind and Polish
I rounded off both ends of the clip with a diamond wheel. To finish it off I sanded both pieces with 800 grit sand paper and a buffing wheel.
I got the knuled screw from ACE hardware. Item # 1501-K, 6-32 x 9/16" in. - Knurled Thumb Screw
Step 7: Make Your Bracelet
The bracelet is made by placing the paracord into the stylus into the shape of a big letter "W". Then you weave the paracord in and out like a figure 8. Check out the video for a better look.
Thanks for reading. Brent