Aluminum Cast Drill Press Knobs

Aluminum Cast Replacement Knobs for the Drill Press

Aluminum Cast Replacement Knobs for the Drill Press

I feel if you have a Metal Lathe, a MIG & TIG Welding Machine, a Milling Machine, and a few friends~ Then many of the rest of one’s Metalworking Shop Tools can be made from scratch.

… I’ll now add a 3D-Printer to the list of those initial tools …

AFINIA 3D-Printer with some Patterns I printed for SuperDave' Project

AFINIA 3D-Printer with some Patterns I printed for SuperDave’ Project

Also ~ One can buy inexpensive and/or used equipment and repair them as new.

Everything on this website is Just-for-Fun, so the process of these projects may not be the most logical because the point is to experience something new and have some fun doing it.

3 Broken Plastic Knobs on My Inexpensive Drill Press

3 Broken Plastic Knobs on My Inexpensive Drill Press

After re-machining and a few simple upgrades, I now really like my 16 Speed Floor Harbor-Freight Drill Press.

The only issues left to fix on it are a damaged top pulley cover latch and the three broken plastic handle knobs.

Close-Up of Broken Plastic Knob Off My Drill Press

Close-Up of the Broken Plastic Knob Off My Drill Press

Over time all 3 of the plastic knobs have cracked and do not tighten on the threaded handles, so I decided to make a 3D-Printed pattern for new  knobs …

SolidWorks CAD Model of the Split-Pattern for the Replacement Knobs

SolidWorks CAD Model of the Split-Pattern for the Replacement Knobs

No special reason for the unusual shape … Just having fun!!  😜

Unusual Shape for the Replacement Drill-Press Aluminum Knobs

Unusual Shape for the Replacement Drill-Press Aluminum Knobs

Once I had a design, then created the Split-Pattern’s .STL files & 3D-Printed …

Knob Split-Pattern .STL File Opened in AFINIA's 3D-Printing Software

Knob Split-Pattern .STL File Opened in AFINIA’s 3D-Printing Software

At the same time, I made several 3D-Printed patterns for SuperDave

3D-Printed Patterns Created for Aluminum Metal Casting

3D-Printed Patterns Created for Aluminum Metal Casting

Mailed the 3D-Printed patterns over to SuperDave for him to cast …

SuperDave’s Metal Casting Sand Flask Mold to Pour in Aluminum

SuperDave was nice enough to send some photos of the casting process …

Close-Up of the Knob's Shape in a Sand Mold

Close-Up of the Knob’s Shape in a Sand Mold

Didn’t sand the knob pattern’s notches because did not mind them rough …

Finished Metal Casting of Knob by SuperDave

Finished Metal Casting of Knob by SuperDave

A few days later SuperDave mailed the Aluminum castings back to me …

He left some as they came out of the sand, so I could see how they were cast.

Group of Metal Casting SuperDave Sent to Me from 3D-Printed Patterns

Group of Metal Castings SuperDave Sent to Me made from 3D-Printed Patterns

Next step was to clean up the Replacement Aluminum Knob castings …

Cleaning the Aluminum Drill Press Replacement Knob Castings

Cleaning the Aluminum Drill Press Replacement Knob Castings

Didn’t buff them too much, just enough to make sure no sharp areas …

Ground and Lightly Buffed the Knobs Sharp Areas

Ground and Lightly Buffed the Knobs Sharp Areas

Clamped down a Hand-Held Mini Belt Sander to help with the clean-up …

Hand Held Mini Belt Sander for Grinding Off Castings

Hand Held Mini Belt Sander for Grinding Off Castings

After the quick clean-up ~ Tapped metric threads into the Aluminum Knobs …

Using a Metric M10 x 1.5 Tap to Add Threads to the Aluminum Knob

Using a Metric M10 x 1.5 Tap to Add Threads to the Aluminum Knob

Once done … Screwed on the Replacement Aluminum Cast Knobs ~ Yay!!

New Aluminum Cast Replacement Knobs on the Drill Press

New Aluminum Cast Replacement Knobs on the Drill Press

I could have purchased new knobs and quickly put them on the Drill-Press …

But … 3D-Printing the Patterns & Aluminum Casting Knobs made it fun!!  😎

Another View of the Old Drill-Press with New Aluminum Knobs

Another View of the Old Drill-Press with New Aluminum Knobs

UPDATE …

At the beginning of this post you can see there is another knob pattern …

3D-Printed Patterns for a 'HURST' Type Shift Knob

3D-Printed Patterns for a ‘HURST’ Type Shift Knob

This is a Shift Knob for my 1999 Jeep … Also made an additional version of the pattern with lettering on it for SuperDave to cast for his projects …

One Half of the 'Hurst' Type Shift Knob on the 3D Printer

One Half of the ‘Hurst’ Type Shift Knob on the 3D Printer

SolidWorks CAD Software allowed me to add a ‘Draft Angle’ to the lettering to make it easier to pull the pattern out of the sand and cast the letters …

Adding Lettering to the Pattern with a 'Draft Angle' to Pull Out of the Sand

Adding Lettering to the Pattern with a ‘Draft Angle’ to Pull Out of the Sand

I based the metal casting patterns off of the old ‘Hurst’ Type Shift Knob …

Jeep Shift Knob Pattern BEFORE and AFTER Buffing

Jeep Shift Knob Pattern BEFORE and AFTER Buffing

Additional Views of the Hurst Type Shift Knob for the Jeep

Additional Views of the Hurst Type Shift Knob for the Jeep

Had to Leave a Few Scratches on the Jeep Knob ~ It's a Jeep Rule :-)

Had to Leave a Few Scratches on the Jeep Knob ~ It’s a Jeep Rule  🙂

I didn’t buff the Shift Knob too much ~ Cause it’s for a JEEP!!!  😜

Once Again ~ Thank You SuperDave!!

Click Here for More ‘METAL CASTING’ items

… CHEERS!!

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4 Comments

Filed under 3D-Printing, CONCEPTS, Metal Casting, PROJECTS, SolidWorks CAD Rendering, WORKSHOP

4 responses to “Aluminum Cast Drill Press Knobs

  1. Pingback: 3D Printed Clone Part Designs | CTM Projects

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  3. Pingback: 3D Printed Chocolate Candy Molds | CTM Projects

  4. Pingback: Markforged Part Design-01 | CTM Projects

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