Well it seems like a week with a lot of discussion about lever caps, and the fabrication of such. Here are some I’ve been working on just this past week.
Ron BreseIf you’re too open minded your brains will fall out.
Edited 4/26/2007 10:14 pm ET by Ronaway
Replies
Beautiful!
George
You don't stop laughing because you grow old. You grow old because you stop laughing. - Michael Pritchard
Ron, how are you doing that bevel-are you belt grinding free hand , milling with a round over cutter , filing or what?
Phillip and WoodDonkey,The drilling is done first after the layout has been done on the bar. The drilling has to be spot on for a lever cap to work properly. I then excavate the excess material for the shape.I have spent a considerable amount of time making guide templates in order to be able to fabricate these things off of templates. Each size requires a different set of templates. In my life before woodworking and plane making, this was what I did for a contract sheet metal fabricator. The chamfer I believe could be done with a carbide tip router bit, given the small amount of material removal. That detail is a chamfer not a round over.The biggest problem, as you know Phillip is holding the little buggers. I work one on each end of a bar until it's too short to hold.To do the large radius shape, I excavate the excess material with a saw and then place it in a jig that rotates on a pin and grinds the radius with a disc sander, once again a different jig for each size lever cap and radius.After that it's just good old fashioned hand work to make it look good, I don't generally work these parts past about 400 grit sandpaper, any finer and the finger prints show excessively.Ron BreseIf you're too open minded your brains will fall out.
Same question as Philip, how was the front edge done? Also how about the chamfer on the back edge, thats pretty good.
Donkey
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