Print

Please login or register.
1 Hour 1 Day 1 Week 1 Month Forever
Login with username, password and session length

[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 ? 
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

[Pat McInnis]

It would be nice to see some images of the homemade tools that people are making.

[Rog]

Thanks for all the v useful suggestions!
I have these ones..but they aren’t that great.
https://photos.app.goo.gl/4kpF5WUC7CrVGhmXA


But if you open this page and search for 'making treble keyboard bending tools' you’ll see some great pix of the sort of thing I want. A decent pair of bending tools can really take the heat out of sorting a ruined keyboard.

http://accordionrevival.com/ACCORDION_REPAIR1.php

[Psuggmog Volbenz]

if you open this page and search for 'making treble keyboard bending tools' you’ll see some great pix of the sort of thing I want. A decent pair of bending tools can really take the heat out of sorting a ruined keyboard.

http://accordionrevival.com/ACCORDION_REPAIR1.php

I just looked at the aove link. All the tools pictured there can quickly and easily be made with a hacksaw and/or small files. Sharp tools and a vise would make this a satisfying, simple project for someone used to working with hand tools, based on my own experiences.

[Rog]

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 [/quote]
This is great. Thanks.

[Broadland Boy]

Where I've needed a bender more blacksmith than watchmaker size using those with pins inserted into strip or bar have been very simple to make - this is where unhardened silver steel (drill rod to our US contingent) as mentioned by Theo comes into its own, I tend to use Loctite retainer or studlock to hold the pins in rather than riveting or soldering / brazing.

[Rog]

How does one harden silver steel?

[Theo]

https://en.m.wikipedia.org/wiki/Tempering_%28metallurgy%29

[Rog]

My experience of working steel is with mild steel, which apparently (according to my extensive research...er...Google search) is 'softer' than silver steel (LOL...soft steel...LOL), which presumably makes it 'easier' to work. It'll certainly be plenty strong enough for basic bending tools.

[Theo]

Yes mild steel is soft and can’t be hardened by heat treatment.  I think you will find that it bends too easily,  or you have to make the tools of inconveniently thick sections.
The clue is in the generic description “tool steel”

[Rog]

I was traumatised by several weeks on the 'fitting' part of Engineering school, which was essentially making things, like a G clamp (I still have it) from blocks of steel, the only tools allowed were files, hacksaw and a drill (there might have been a shaping m/c as well...dangerous blimmin thing). It was everyone's least favourite time (at least 6 weeks of it). I came away with excellent filing skills...but we worked mild steel so the thought of working something harder makes me shudder ...brrr..

[Theo]

Its not as hard as reed steel!

[Rog]

This is true. And it has occurred to me many times that our files were probably as blunt as hell. The instructors no doubt thought it character building......the discipline was more British Army than school teacher (am I hurting you son? No sir. I ought to be, I’m standing on yer 'air...get it cut...or wear a hair net).

[John MacKenzie (Cugiok)]

While browsing I found this excellent wire bending tool. I can see all sorts of melodeon applications for it.


SJ

http://www.ncsl.co.uk/wirebender/

[Graham Spencer]

While browsing I found this excellent wire bending tool. I can see all sorts of melodeon applications for it.


SJ

http://www.ncsl.co.uk/wirebender/

Looks perfect for making replacement springs, among other things.

[Graham Spencer]

While browsing I found this excellent wire bending tool. I can see all sorts of melodeon applications for it.


SJ

http://www.ncsl.co.uk/wirebender/

Looks perfect for making replacement springs, among other things.

On second thoughts, having watched the "how-to" video, it would be a bit heavy-duty for our needs. A similar tool on a smaller scale would be excellent,though.