Here are a couple more images of the process of machining the lever, which I managed to complete last night.
I attempted to limit the machining processes as much as possible to left hand cutting operations to keep tool changes to a minimum, but the inside radius of the handle needs another tool and is best cut in the other direction.
Here is the scratch pass of the threading operation. I paused after this to check that the thread pitch is indeed 1.5mm.
Then, some 47 passes later, the threading is pretty much done.
A fair amount of sanding and polishing later and here is the finished part on the right with the original and the steel from whence it came on the left. As a side note, the threading at the small end of the lever that keeps the handle in place turns out to be imperial 5/16 - 18. Probably because they could't get the rather exotic blind nuts from a metric supplier. This makes it the one single exception to the otherwise absolute metric rule of the machine.
I attempted to limit the machining processes as much as possible to left hand cutting operations to keep tool changes to a minimum, but the inside radius of the handle needs another tool and is best cut in the other direction.
Here is the scratch pass of the threading operation. I paused after this to check that the thread pitch is indeed 1.5mm.
Then, some 47 passes later, the threading is pretty much done.
A fair amount of sanding and polishing later and here is the finished part on the right with the original and the steel from whence it came on the left. As a side note, the threading at the small end of the lever that keeps the handle in place turns out to be imperial 5/16 - 18. Probably because they could't get the rather exotic blind nuts from a metric supplier. This makes it the one single exception to the otherwise absolute metric rule of the machine.
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