My 3D-Printer is making me Lazy ( and I Love it )
One can assume there are many ways to make angled steel washers, and probably even more places to buy several.
However, it was 10pm at night and I needed 32 Angled Washers in the morning and a way of making them.
As usual I looked to the 3D-Printer for a quick & easy solution.
Luckily, years earlier, I didn’t listen to warnings from naysayers that said ABS filament 3D-Printers were just toys and could not make usable parts… because my workshop is full of ‘usable’ 3D printed parts.
Sometimes the simple items are the most helpful …
.STL files for 3D Printing items can be found on GrabCAD.com
Long story short – I designed a fixture to fit inside the clamp on my metal band-saw to cut angled washers.
In the morning, my plan was to bolt together a project made from steel Channel with inner sides that have an approximate 9 degree angle.
When cutting several holes in the sides of the channel I ended up with a few ready-made angled washer plugs and bored them out with the metal lathe to fit 3/8″ bolts … However, I needed a lot more angled washers.
Looking at the Hole-Saw slugs gave me the idea of creating more angled washers.
I used 3/4″ mild steel rod and bored 3/8″ holes in each end of the rod …
The plan was to cut angled (9 degree) cuts on each end and then cut another set of straight cuts on each end to create washers …
Was not sure if the 3D Printed ABS would hold the rod tight enough in the band saw’s clamp, so I put some vise-grip pliers on the other end of the rod to keep it from spinning …
The 3D Printed ABS split fixture more than held the rod tight enough …
Every cut creates an Angled Washer from the 3/4″ round stock …
Outer edge starts out straight … then the first cut creates the 9 degree side of the angled washer … then rod flipped around …
After both ends are cut angled, then the 3D Printed fixture is removed for the straight cuts. Many Washers can be made switching back and forth from Straight to Angled Cuts
Process continued until I had enough angled washers to complete my project.
It worked great!!
Once again ~ Sometimes the simple items are the most helpful.
While I felt a bit lazy starting a 3D-Print and then going to bed to wake up the next morning with a finished part – I am quickly getting over the guilt. 😉
BTW ~ The reason the Workshop Press looks so unusual is because the parts store together as a Press, however, it can transform into 3 additional workshop tools … Sheet Metal bending Press Brake, a Pipe Bender, and a Hoist.
CHEERS!! . . . CHARLES MARLIN ( @MetalDesigner )