Machined my own bolt knobs

[Dave Hoback]

I started with this one made from Delrin polymer. It was a test to make certain this would work before I went with other material. Started with a bar of black Delrin I had and turned it to about 1” round as I do small parts, using my mill.
https://i.ibb.co/31SbQmZ/E59-D69-F8-949-F-4-BCB-B186-60-EEFE417-B01.jpg (https://ibb.co/6YDSL0C)

Drilled/tapped. Machined-ground the contour using my 2x72 belt grinder.
https://i.ibb.co/4Y19pfR/6793-E148-3486-4-B64-B531-14-D7059-F8-B99.jpg (https://ibb.co/SdfWBxw)



Knowing this would work, I ordered some 6AL4V in 22mm round bar.
https://i.ibb.co/xCd7d0z/D8-A35708-7522-44-F0-BF81-15-ACCC9-BC9-CE.jpg (https://ibb.co/mDgcgwh)

Drilled & tapped 5/16-24 & cut to 1.5” starting length on bandsaw. Machined the contour similar to Badger. Came out very nicely & will match well to my new Titanium Bolt Handle. I will post more pictures after I sand blast & Cerakote. This along with the bolt handle, I have 14 small parts to Cerakote. (Always the little pieces, ya know..)
https://i.ibb.co/wLD4wz1/AC025-B67-F5-DF-4029-80-C2-109-BD1-E1-E2-E7.jpg (https://ibb.co/mBQ4Xc7)

https://i.ibb.co/VHmbGF4/6930-B670-3420-4682-82-CD-616-BCA103472.jpg (https://ibb.co/f8vZW3w)

[CFJunkie]

Nicely done, Dave
Beautifully machined and I'm sure it will look great.

[jkv45]

Nice work there Dave!

[jpx2rk]

Very nice work. congrats.

[PhilC]

Very nice Dave!

[tomme boy]

Did you use a rounding fixture tool post? They make easy work doing stuff like this

[Robinhood]

I wish I could see the pictures. It sounds similar to the way I do mine. I used round stock(drill rod) and aluminum for the heads. Mostly done in a mill and a colet lathe.

[Dave Hoback]

I wish I could see the pictures. It sounds similar to the way I do mine. I used round stock(drill rod) and aluminum for the heads. Mostly done in a mill and a colet lathe.

Its odd you can’t see these Robin. Even if you click the link? They are just 3rd party from IMGBB. Yes, we’ve talked about turning in a mill before. ;)That’s what I do. But only small objects. And only to round & bevel edges. I can’t contour with this setup. I contour the old fashioned way. Grinding on my 2:72 belt grinder, which is incredibly powerful! 20 wide x 72” long ceramic belts will eat steel, Aluminum, Titanium like it’s Balsa wood!

[Dave Hoback]

Did you use a rounding fixture tool post? They make easy work doing stuff like this

Actually no. I know exactly what you mean, but for something like this, I grind the bevel angle first. Similar to grinding the primary bevel on a blade. This sets the minimum diam. almost to where it meets the bolt handle. About .460” diameter. Then I grind the flat in a convex shape. Because of years grinding blades, I have the control for this without a guide.

[Robinhood]

Tomme,

I decided i liked the round ones so I TIG'ed some bearing balls (around 7/8" diameter) to the end of some drill rod after I ID threaded 1/4-28 the other end. Cut the bolt handle off, milled it flat and perpendicular to the axis, tapped the flat the same in the middle of the handle where I cut it off. Used some all thread and red loctite to tie it together. Blended the transition with a set of files and some sandpaper....and done. Fortunate for me at the time I had access to a full. Really like these kind of post where others share ideas!!!

Dave,

It is rare I miss pictures but in this case I don,t even see links.

[PhilC]

This is the last pic can you see it when you click the link?

https://i.ibb.co/VHmbGF4/6930-B670-3420-4682-82-CD-616-BCA103472.jpg

[Dave Hoback]

Tomme,

I decided i liked the round ones so I TIG'ed some bearing balls (around 7/8" diameter) to the end of some drill rod after I ID threaded 1/4-28 the other end. Cut the bolt handle off, milled it flat and perpendicular to the axis, tapped the flat the same in the middle of the handle where I cut it off. Used some all thread and red loctite to tie it together. Blended the transition with a set of files and some sandpaper....and done. Fortunate for me at the time I had access to a full. Really like these kind of post where others share ideas!!!

Dave,

It is rare I miss pictures but in this case I don,t even see links.

Great post Robin. I’m right there with you compadre. I absolutely love these threads. Different people discussing & going into specifics of how they do such & such a machining project. It feeds the machinist in me! Gives me such a sense of pride; then reverence when I see & hear what others are doing! Great stuff.