Discussions > Instrument Design, Construction and Repair
Lever bending tools
Rog:
I’ve got a few lever bending tools but I want to make some more. The slots on the ones I have aren’t always the right depth and or width. Any tips for materials/technique for machining a slot in steel...or other ideas on making benders? I don’t have a milling machine...so is it hacksaw and file? Or some drill attachment?
Winston Smith:
I came across some fairly woodscrews (for decking possibly?) in one of my old sweetie tins. Hammered the end flat, filed off the few threads, drilled a hole through of the right size and then hacksawed into the hole from one side. After a bit of cleaning up with a small file, I was then able to bend it to get the leverage I wanted. I've made one or two which serve me well.
Theo:
I use silver steel bar (a widely available too steel). I make the slot using needle files. The material comes in a semi-hard condition that will cut with hacksaw and file. I should really have hardened them, but they have lasted several years without.
rees:
I use a thin disc in an angle grinder.
Broadland Boy:
Hi Roger, what's old NCB sat on and bent then ? :o
Without a lathe or mill, slitting saws are out of the question 'handheld' but hacksaw is OK as are jewellers piercing saws for smaller slots. Old pc printers can yield very nice round or square barstock for nothing and the thin slitting discs Rees mentions can be used on a small bench grinder or a clamped angle grinder very effectively.
While there are not many on today, searching for GPO tool or strowger tool can yield ebay hits, some at a price that makes DIY senseless but mainly inspiring ideas for designs or shapes that you can then mimic - make them in pairs - see
https://www.ebay.co.uk/itm/8-x-Post-Office-PO-Tools-Engineering-As-Photo/162013954819?hash=item25b8c8c303:g:QwkAAOSwwpdW8BOL:rk:8:pf:0
https://www.ebay.co.uk/itm/Vintage-GPO-Tools-x2-Other/163418119385?hash=item260c7a9cd9:g:9iYAAOSwD1pcAvtV:rk:5:pf:0
https://www.ebay.co.uk/itm/Vintage-GPO-Adjusting-Tool-for-Relays-1947-I-N-T-2-P-E-C/153269307949?hash=item23af900a2d:g:PNYAAOSwikpb5Zkl:rk:32:pf:0
I'm fortunate in having a nice selection from Dad, who was in the private phone, tannoy & masterclock sector
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