Frank Ford -
I've been making these string winders for a few years now, and here at the shop they've been a point of conversation over their various features and styles. Once folks find out that I actually do all the operations myself, the most popular question is, "How do you make the eighty-three degree angle on the handle?"
So, just for fun, I thought I'd post some photos of the process.
After I drill the 1/2" brass ball to accept the 1/4" diameter aluminum crank arm, I apply a small drop of a special Loctite retaining compound. This anaerobic adhesive is catalyzed in the presence of metal, and in this application, achieves about the same strength as an interference, or press-fit:
And I insert the rod into the hole, where the green compound will lock it permanently in place within a few seconds:
Then it's over to my tiny Rusnok milling machine to drill the ball for that 83-degree handle bearing. In order to achieve repetitive alignment, I've milled a pair of "soft jaws" in the mill vise to hold the rod and ball assembly with rigidity and precision in a cavity that exactly matches its profile: New for 2018 - Matched Sets of Acrylic Handle Cranks!
Then, a vertical drilling operation gives me that angle automatically:
Another drop of that magic green fluid secures the 3/16" diameter steel bearing:
Here's a cutaway view of the final assembly - note that the smaller rod is drilled through both the ball and the larger rod, making the joint incredibly solid and secure:
Once the arm is assembled, I can hold it in my special little fixture that keeps it aligned while I whack it with a steel stamp:
None genuine without this brand: New for 2018 - Figured Koa Handle Cranks!
Coming soon - Part 2 - The Crank Handle Bearing