Had a chance last night to go through the process and take pictures for posterity.

Won’t be taking them in for plating any time soon. 

Get ready

Use a little bushing I made to center. 

Squish!

Cup made

Turn die over, put cup underneath and squish the wings flat. Makes the machining steps easier

 

 

Part two.

Use die to drill 21/64 hole

 

Install on custom mandrel on the lathe and remove excess.

Parted off to right length. Quick sand paper polish while it’s spinning. 

Flash clean up on the inner edge of the parted cut complete. 

 

Final stage, a bit of dremel work to clean up any burrs and rough edges. 

Scratches on the back side need to smoothed from contact area on the mandrel. Quick abrasive rub, then sandblast for consistent finish. Off to plating with the next batch of hardware. Hopefully not too far in the future....

Edited March 16, 20205 yr by zKars

Man-hours per piece?

Dennis

Awesome. When you said you were going to cut off the excess material on the lathe, I was going to suggest trepanning. I suspected that if you tried a traditional outside edge cut, there was no way you were going to be able to do that mounted on a mandrel like that. The interrupted cut would have made that impossible. Either the part would spin on the mandrel or the corners would have just bent over. Seems you're a step ahead of me!

Looks great!

14 minutes ago, psdenno said:

Man-hours per piece?

Counting his, mine, and granny's? About 40.    

2 hours ago, zKars said:

So? How about a close-up of one of yours next to a stock one??

And just think... In the beginning, it was a pipe dream and all sounded so difficult!   

See post # ... oh wait, no post numbers. Page one, 3/4 of the way down.

 

Edited March 17, 20205 yr by zKars

5 hours ago, Captain Obvious said:

Counting his, mine, and granny's? About 40.    

At a reasonable $100 an hour......only $4,000 per washer.  Any price break if I buy a pack of six?  ?

21 minutes ago, psdenno said:

At a reasonable $100 an hour......only $4,000 per washer.  Any price break if I buy a pack of six?  ?

Given the tough position so many of us are probably in or going to be in soon, you can have 6 for $4k. Canadian. 

Good news is I’ll lots of time to make plenty. Got a big sheet of 18 gauge to gobble up.

Progress today. Cup washers are back from the plater. Look good to me!

Now I have to go buy more plumbing rubber washers to complete them. 

 

 

By “go out” I of course mean, order on line. I found some at Ukrainian Tire. Coming next week. Never ordered anything from CDN Tire. usually it’s a reason to go out for a look-see, like Princess Auto or Harbour Freight.... 

 

Edited April 2, 20204 yr by zKars

Excellent forgeries Jim!!!