|
|
My customer made a custom door, which was considerably thicker than a standard door. This meant that standard door knob hardware would be too short to reach through the door. Door knob extension kits are available, but these were also too short. To solve the problem my customer purchased a second door knob assembly so that he could scavenge the two shaft parts that were required. The task was to weld an extension to the outer piece that looked like half of a pipe. The inner piece appeared to be made of pot metal and I was reluctant to attempt to weld it. I know that Muggy Weld makes a Super Alloy 1 product that can weld pot metal, but a kit costs $105. My customer and I decided to machine a sleeve to extend the shaft, which would be glued on using Loctite 680. The first picture shows the drawing and the parts that my customer provided.1. Drawing and parts
I was concerned that the sleeve would interfere with the numbs on the ID of the shaft so I ground them off. 2. Grinding off nubs
I like to remove the plating before I machine plated metal to avoid smearing the plating on the area to be welded, because the plating will cause porosity in the welds.3. Etch off plating in HCL
4. Plating removed
The first machining task was to remove the radius on the end of the shaft in preparation for welding. 5. Squaring off one end
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:Next, I trimmed the end of the outer extension shaft.6. Trimming off the other end
Below are the machining tasks that were performed on the inner shaft.7. Facing end
8. Center drilling
9. Turning OD
10. Nice coil chip
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:Here are some additional tasks for the inner shaft.11. Parting shaft
12. Drilling shaft
13. Reaming shaft
Next, I sanded off the mill scale in preparation for welding.14. Grinding off mill scale
Now I was finally ready for welding.15. Setup for welding
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:Now the welding steps:16. Ready to tack weld corner
17. Welded out
18. Close up of weld
I didnt want to penetrate on the inside, because it would interfere with the inner shaft.19. Inside of weld
The next step was assembling the inner shaft with 680 Loctite.20. Sleeve Loctited
Smith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:Here is the painted shaft.21. All done and painted
And here is the whole latch assembled.22. All done and painted
-DonSmith Oxyacetylene TorchMiller Dynasty 200DXLincoln SP-250 MIG WelderClausing/Coldchester 15" Lathe16" DuAll Saw15" Drill Press7" x 9" Swivel Head Horizontal Band Saw20 Ton Arbor Press BridgeportLincoln LE 31 MP & Lincoln 210 MP
Reply:I just use Schlage locks, they can do up to 2” without doing anything. Extension kits are about 15 bucks.
Reply:
Originally Posted by walker
I just use Schlage locks, they can do up to 2 without doing anything. Extension kits are about 15 bucks.
Reply:Beautiful work!
Reply:If you weld the key in, you'll never lose it
Reply:Well done!Lincoln 350MPMillermatic 350PSyncrowave 2501969 SA200HTP Invertig 221
Reply:Nice work Dongood thing you are retired....
Miller 211Hypertherm PM 451961 Lincoln Idealarc 250HTP 221 True Wisdom only comes from Pain.
Reply:Darn nice work. Just keep in mind a good locksmith shop or door hardware supply vender can provide knobs for such problems. Got to pass up the box store stuff. Being to provide it in the style the customer wanted? On time ? Probably not, and thats when skills such as yours become so handy. Once again impressive work.
Reply:Nice job, and a really good job on the documentation. I really like that third hand you have there. Ground clamp, ground strap, adjustable, and bronze feet. Where did you buy that ? I could certainly use one in my shop.Thanks for sharingAirco 250 ac/dc Heliwelder Square waveMiller Synchrowave 180 sdMiller Econo Twin HFLincoln 210 MPDayton 225 ac/dcVictor torchesSnap-On YA-212Lotos Cut60DPrimeweld 225 ac/dcPrimeweld mig180Miller AEAD-200
Reply:
Originally Posted by albrightree
Nice job, and a really good job on the documentation. I really like that third hand you have there. Ground clamp, ground strap, adjustable, and bronze feet. Where did you buy that ? I could certainly use one in my shop.Thanks for sharing
Reply:If I ever need to make a living on my welding skills... I want every random customer to provide parts and drawings like yours! Beautiful work!
Reply:You obviously have the patience of Job and great attention to detail. Nice workGeezerPower Mig 255C185 TIGBlue 175 MIGRanger 8 Kohler 20HP1974 5K Lincoln/Wisconsin Powered (Cherry)Victor/Harris O/AK 487 Spool Gun
Reply:Looks great.I had do that a few times myself. Dave
Originally Posted by Don52
My customer made a custom door, which was considerably thicker than a standard door. This meant that standard door knob hardware would be too short to reach through the door. Door knob extension kits are available, but these were also too short. To solve the problem my customer purchased a second door knob assembly so that he could scavenge the two shaft parts that were required. The task was to weld an extension to the outer piece that looked like half of a pipe. The inner piece appeared to be made of pot metal and I was reluctant to attempt to weld it. I know that Muggy Weld makes a Super Alloy 1 product that can weld pot metal, but a kit costs $105. My customer and I decided to machine a sleeve to extend the shaft, which would be glued on using Loctite 680. The first picture shows the drawing and the parts that my customer provided.1. Drawing and parts
I was concerned that the sleeve would interfere with the numbs on the ID of the shaft so I ground them off. 2. Grinding off nubs
I like to remove the plating before I machine plated metal to avoid smearing the plating on the area to be welded, because the plating will cause porosity in the welds.3. Etch off plating in HCL
4. Plating removed
The first machining task was to remove the radius on the end of the shaft in preparation for welding. 5. Squaring off one end
Reply:Nice work, Don!
. Not that any of us are surprised lol. Sent from my iPad using Tapatalk:
Reply:Very nice work but your buddy bought the wrong lock set. I too built my own outside doors and had to do the same exact thing. Some locksets use a square rod instead of that rounded one. I used key way stock the same size as the square rod in my lockset. I just had to thread each end. My door was about 3" thick. Oh, don't forget that you will also have to make a new strike plate with the little square hole in it.
Attached Images
Reply:
Originally Posted by Bob
Very nice work but your buddy bought the wrong lock set. I too built my own outside doors and had to do the same exact thing. Some locksets use a square rod instead of that rounded one. I used key way stock the same size as the square rod in my lockset. I just had to thread each end. My door was about 3" thick. Oh, don't forget that you will also have to make a new strike plate with the little square hole in it.
Reply:Wow very nice. That’s a great idea and write up.Retired Old GuyHobart 210Lincoln AC/DC 225/125 Tombstone Evolution 14 Saw
Reply:wrong threadLast edited by farmersammm; 2 Weeks Ago at 10:33 PM. |
|
发表于 2022-5-19 11:02:49