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Working With Brass
I looked high and low for some brass and this is all I
had. However, this will be more than enough for what I need. The small
piece on the left and the long piece on the right are 1/2" diameter. But
I'll need to take a clean-up cut on them both, which will bring the
outside diameter down a little smaller. This is why I choose the
undersize end mill earlier.
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I turned the outside diameter to .474"
diameter so it would slide into the hole on the handle. I'm not looking
for a press fit here, I'm going use a chemical bond.
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Here are my brass inserts ready to be installed. If you're wondering
what the grooves are for, they're for the chemical bonding, or epoxy.
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I'm using some 60 minute epoxy so I can take my time
installing each one. After mixing the epoxy, I placed the insert on
a steel drive punch to make it easier to apply the glue using a small
paint brush. This method kept my fingers much cleaner so I didn't get it
all over my wood pieces.
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I made the inserts a little longer than the thickness of my handles
(.010" long) which I'll sand once the epoxy sets up.
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I stored them this way while the glue dries, which worked out great.
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The next day I used my D.A. sander along with my sanding block to remove
the excess brass.
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This process didn't take long and went smooth.
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Last I used my milling machine to chamfer each side of
the inserts by hand. Now that the brass inserts are finished, I'm going
to add some small rubber feet to the bottom of each board.
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Working With Rubber
I looked at everything that I had to use as rubber feet but
couldn't find anything that was small enough. Then I looked online for some,
but didn't see anything I really liked there either. So that measn I'm going to make my own
rubber feet out of some rubber that was used as packaging that I saved
from years ago.
This angle rubber has two thickness': one is just under 1/8"
and the other is close to 3/16" (arrows). The thicker stuff should work great for what I've got in mind but I'll have to cut them out
first.
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