I was a little burned out on this project after October, but after a two month break, I have the proton pack bug again! While I was at my parent's house over the holidays, I took advantage of their better equipped shop to work on the ion arm cap and the banjo fittings.
Starting with hunk of
1" x 1/2" aluminum stock, I marked and center punched the location of the holes:
Then bored and counter bored the holes:
Swarf can be sharp!
Drilling more holes:
Tapping the hole for the 10-32 Clippard fitting:
My cousin is a machinist and he was nice enough to knurl the copper rod for me:
Here is a test fit of the copper rods after a quick polish of the parts:
On to the banjo fittings!
Here is my starting material,
3/8" square brass stock, and
1/4" brass tube:
I started with the hose fittings- cut the tube to length, square the ends, and polish:
Who needs a lathe when you have a drill press and dremel?
The top piece has an ugly end where I practiced my technique:
For the body of the banjo fittings, I cut the stock to length, squared the ends, etc, etc:
Drilled and tapped the 10-32 hole for the screw:
I didn't have a 4 jaw chuck (to turn the work piece), so I had to drill out the inside the hard way. I starting by finding and punching the center of the end face:
Drilling out the inside:
On the first one I made, I made the mistake of drilling out the inside before drilling and tapping the hole for the screw. It made
drilling and tapping the hole much more difficult because the drill bit would wander due to the variable wall thickness, resulting in a large oval hole.
Here they are after adding the wire management holes and test fitting the tubes:
Now I just need to chamfer the corners and cut the tubes in half.