Subject: Re: How do YOU make round washer-shaped 4130 parts?

From: Steve Wellcome <[email-masked]>
Date: 25 Jun 1996 11:53:56 GMT

A lathe.

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From: Steve Wellcome <[email-masked]>
Date: 25 Jun 1996 13:53:14 GMT

Opps - back up.  I notice you're planning to start off with stock
of the required thickness.  I would (probably) use a lathe, and
part off the pieces from round bar of the proper diameter or,
depending on how good the finish needed to be, alternate between
drilling a center hole on the lathe and then sawing off a bunch
on the horizontal bandsaw until I ran out of hole.

If you start with sheet stock with the idea of cutting them with
a hole saw, assuming you can get a hole saw of the proper size
with a center pilot drill of the proper size...that ought to
work pretty well too.  You'll want stock narrow enough so you can
clamp it down on the drill press table.  

A lot depends on how accurate to size they need to be and how
good a finish you want.

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From: [email-masked] (David Munday)
Date: 25 Jun 96 14:12:59 -0500

In article <[email-masked]>, [email-masked] (Bill Strahan) writes:
> Lee McGee <[email-masked]> wrote:
>>--
>>I need to make a bunch of round washer-shaped parts (one inch,
>>7/8 inch diameter) out of .090 and .063 4130N.  These have holes
>>in the center, either 3/16 or 1/4".  They'll be used as weld-in
>>reinforcements where bolts go through control sticks, etc...
> 
> Something I used to do when making wooden washers for airgun silencers
> (don't ask) was to mark the pattern on the material and center the
> hole then drill the hole and cut the washer roughly to shape.  Once I
> had several cut out, I'd put them all onto a bolt the same size as the
> hole and tighten a nut onto them.   Then I would put this in a drill
> and spin them against sandpaper.  I'm sure you could do the same
> against the side of a grinder.  This way they are all the exact same
> size and are perfectly round.
> 
That's more or less what we did to make washers to reinforce the elongated gear 
attach fittings on the chapter champ.

The bolt was chucked up in a lathe though.

-- 
Dave Munday  -  [email-masked]  -  [email-masked]
Web Page:  http://ourworld.compuserve.com:80/homepages/munday
PP-ASEL  -  Tandem Flybaby Builder  -  EAA-284 (Waynesville, OH)
Those who beat their swords into plowshares will plow for those who do not.

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From: [email-masked] (Edward Haas)
Date: 25 Jun 1996 09:58:05 -0700

--Getcher self a Whitney punch, or something similar. The 
distinguishing characteristic of these is that the punches have a little 
pip in the center. Punch the o.d. first, then go back, center in the 
depression made by the pip in the first operation and punch the i.d. 
Clean up the burrs on a belt sander (fun if they get away!) or a bit of 
sandpaper.
-- 
	"Steamboat Ed" Haas	:	Learning to say NO is harder 	
	COMING SOON		:	than learning to say YES...
	http://www.west.net/~steamer  	
		---Decks a-wash in a sea of words---

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From: [email-masked](James I. Lewis)
Date: 26 Jun 1996 06:30:29 GMT

>A lathe.
If just for reinforcement, why not AN-970 fender washers (4130)? Just
use your belt sander to remove the plating where the weld will go.

Of course I'm lazy.

Jim

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From: [email-masked](James I. Lewis)
Date: 26 Jun 1996 06:36:07 GMT

In <1996Jun25.141259@miavx1> [email-masked] (David
>The bolt was chucked up in a lathe though.

This is a good suggestion. I've done this before but I have a lathe and
and was able to machine the outside diameter. Sans a lathe the sander
should work well.

Just an opinion mindya.

Jim

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From: [email-masked] (Edward Haas)
Date: 26 Jun 1996 10:08:58 -0700

Edward Haas ([email-masked]) wrote:
: 	--Getcher self a Whitney punch, or something similar. The 
	--Whoops! This device would have a problem with material as thick 
as .090in. It's really suited to thin brass, etc. Sorry about that...
-- 
	"Steamboat Ed" Haas	:	Learning to say NO is harder 	
	COMING SOON		:	than learning to say YES...
	http://www.west.net/~steamer  	
		---Decks a-wash in a sea of words---

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From: "Dennis J. Brown" <[email-masked]>
Date: Tue, 25 Jun 1996 22:16:28 -0700

> The bolt was chucked up in a lathe though.
The best way is to take bar stock, turn to the right diameter and 
then drill a hole of the proper size. Next with a cutoff tool cut 
them off at the right length. I do this all the time have made small 
brass washers down to about .005 in thickness

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From: [email-masked] (Gregory Travis)
Date: 27 Jun 96 01:23:02 GMT

>The bolt was chucked up in a lathe though.

Doesn't the heat of sanding tend to ruin the temper of the steel?

"or are you just REALLY patient?" greg
--

greg		[email-masked]	http://gtravis.ucs.indiana.edu/

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From: "John R. Johnson" <[email-masked]>
Date: Thu, 27 Jun 1996 10:56:43 -0500

> "or are you just REALLY patient?" greg

I chuck them up in the lathe and use a file.  4130 files nicely.
John

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From: [email-masked] (David Munday)
Date: 30 Jun 96 18:30:00 -0500

> "or are you just REALLY patient?" greg

And welding it on won't?  Actually we didn't sand it we cut it.