Sunday, July 22, 2012

DIY Metal Brake (continued 1)

STEP 3: Ahhhh, Screw it!
Let's assemble the parts now.

Using four #8-32 x 3/8" machine screws along with lock washers and hex nuts, attach the hinges to part C as shown in image 9.
Image 9: Hinges attached to part C

Again, note that the rounded part of the hinge should be flush with the L bend in part C. Now attach part D to the hinges using another four #8-32 x 3/8" machine screws, lock washers and hex nuts. You should now be able to bend the hinge with parts C and D attached. You can create an X configuration (image 10) or a T configuration (image 11, looking at the top of the T) based on how it is bent.

Image 10: X Configuration of parts C and D

Image 11:  T Configuration of parts C and D

Image 12 shows all of the parts left to be attached to one another in roughly the positions they will be attached. Attach part A to part C (upper right in image 12) using the one hole left in each part along with one #8-32 x 3/8" machine screw, lock washer and hex nut. Image 13 shows part A connected to part C (left side) as well as part B connected to part D (right side). When you connect part B to part D you will want to use one of your long #8-32 x 1" machine screws and do not put a lock washer or hex nut on it. I also inserted a hex nut between parts B and D to reduce the parts from rattling around when the tool is not in use, however, this is not necessary (image 14).

Image 12:  Rough positioning of parts left to be assembled

Image 13:  Parts A, B, C and D attached

Image 14: Hex nut inserted between parts B and D

Once you have everything looking like image 13, flip the tool over (image 15), and insert the other long #8-32 x 1" machine screw through the final hole in part D.

Image 15:  Tool awaiting second 1" machine screw

Then, place the flat steel plate on the two long machine screws and place two wing-nuts on the screws (images 16 and 17).

Image 16:  Flat steel plated placed on long screws, wing-nuts in place

Image 17:  Wing-nuts holding flat steel plate on part D

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