Went out this morning and let out the wife's Chickens...
Poured a fresh cup of coffee,
and got started in the shop.
The first task this morning was the cross pin for the crank handle. This would be a multi-step process and slow and careful. Didn't want to screw this up and have to make another crank.
First, was to make a reference line on the crank. Didn't want to make a pencil line that might leave residue. No marker or chalk. What
....
That old standby... painters tape.
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Next question. How do I hold the crank assembly level and steady and work the handle on the drill press? That's easy, put it in the drill press VISE, but pad the vise so IT doesn't leave marks.
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Drilling the holes thru the crank was a three step process. Each required that the crank, held in the vise, be aligned and the depth be set for that pass.
The first pass, was for a hole to be drilled that was the same size as the outside diameter of the threads on the torx screw I would use as the cross pin. No need for the pin to lock into the first half of the crank. So, the first pass would only cover the first half.
The second pass would be in the off side of the crank and would be just under the size of the threads on the torx screw, and would be the same bit I would use to drill thru the axle. (dowel.) This pass would only go halfway thru the off side.
The third pass on the drill press would countersink the entrance to the crosspin channel.
Each of the passes were performed without a hitch. Each step was set up, a test pull with the vise and it's contents BEHIND the bit was performed and then the vise was moved into position and secured and a slow pull performed the pass.
Yup, the pucker factor was present, but not too bad. Good preparation reduces the chance of error. (knock on wood.)
Next step was to drill thru the axle, and using the crank itself as the guide would reduce the chance of error. I set up the tumbler in the position so the down crank handle would put the logo out front and the open hatch at the top so tournament folks could toss in raffle tickets. Got everything just so and Blocked the bottom of the tumbler so it couldn't move and clamped the crank so it was tight against the spacer.
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Took a deep breath, and drilled. Boo Yah. It was easy to determine how far to drill. I had resistance while drilling thru the axle, but when it cleared, I felt the bit slip into the void on the off side. I removed the crank, blew out the sawdust, and then installed the pin. The crank was now locked to the tumbler.
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Next task was to install the end caps. To do so meant cutting off the excess length on both ends of the axle. Hmmm... first we need to know how deep the caps are. Measurements again. This time we'll use the digital caliper.
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To get an accurate measurement, I lay a steel rule across the open end of a cap, and then measure the depth with the caliper.
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As you can see by the pictures, we have a depth of just over one inch. I will cut the exposed ends to just UNDER one inch so the caps will fit flush. First though, I will cut a countersink in the ends of the caps to allow for a contrasting plug to hide the screws after installation.
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I marked the crank end first and made my cut with a Japanese pull saw. They make the smoothest cuts and are razor sharp. Cap installed and plug in place. Once it dries I'll cut it close with the saw, then cut it flush with a freshly sharpened chisel. (Those pics will follow.)
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Repeated the process with the other end, and now the tumbler could be used.
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The only tasks remaining are adding the base, trimming those two plugs, and the enhancements I mentioned in the last post, which could be done without. The base will add weight and stability so it's definitely happening.
This turned out as I had hoped, but is not what I pictured when I started. Like most of my original constructs, they change on the fly, but usually work out. (To be fair, I have had a few end up as scraps and kindling.) I can't take full credit for all the ideas. Using magnets for door closures is advertised on the Lee Valley Website and I have seen them used for Tumbler hatch closures on YouTube posts. Not much new these days. I have to thank those who post on You Tube and share their ideas. Much of what I have learned over the years came from other woodworkers on forums, or from You Tube posts... much came from woodworking magazines. Some I pulled out of the air, discovering there are easier ways to do things.
I hope you guys enjoyed the post.
As long as folks enjoy them, I'll keep posting.
Regardless, I'll keep taking pictures of the progress of my builds, I do that for myself and keep them in case I go back years later and want to do the same project again. It helps ME remember how I did things.
)
