4th Annual BLF/OL Scratch Made Light Contest- Hand Made 10/31 finished

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MtnDon
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Looking very nice!
Rufusbduck
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Thanks, I haven’t ruined it yet. Smile

Cutting the tube.

I was home for just long enough to clamp my pull saw to the drill press table and spin the wood tube by the blade making 3 cuts. The first was at the tail to remove the bad part. The second was a few mm lower to get a piece for the tail cap, and the third at the other end to size it. Here again after that first cut. And how the cut looks. The blade is only about a half mm thick so I’ll be able to line up the grain pretty well when I assemble it. Here are all the cut pieces.
Squaring things up

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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Looking good. Love
I’m not sure if you have mentioned it, what are you going to finish the Burl with?

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Rufusbduck
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A liquid epoxy.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Rufusbduck
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Squaring up some loose ends. This is the end of the copper core, as you can see it’s not quite square. Some sanding took care of that. The failed battery tube supplied a piece I will use for the tail cap. It’s close to the right size already but also isn’t quite square. All of this is under wood and epoxy and not visible but at least it’s now sanded square. Here again after filing and sanding the OD’s to match. Fritz had asked earlier whether brazing was complete between all the surfaces. Well, not quite. Since these bands were very tight in order to hold the seam shut it probably prevented even wicking of the silver solder. In any case the long seam is fully wetted and that’s the critical one. A few more bits of brass will be added to that little tail piece including a fresh piece of threaded copper. The one in the pic is from last year and not legal to use as part of this build so I only use it for test fitting.
Oops II

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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Illegal bits used in your build? I’m glad you owned up as I would of twigged eventually, not. Smile
Maybe we should be doing drug tests as well? Then maybe not, there may well be anyone left in the comp. Facepalm
Another saw blade. At least this one is static. Just keep your fingers away from the gap. As usual loving your work RBD.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

FmC
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Looking good, RBD Beer

I thought it was mentioned in the rules this year that each entry was going to be swabbed?? Wink

Rufusbduck
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Nothing but ibuprofen I swear. Innocent

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Rufusbduck
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Bad news first. The MkII battery tube I fell afoul of poor logistics on my part and sufferered some kind of mischance(probably slipped in the shower). Here are it’s remains alongside the MkIII tube. I ran into a problem after brazing the stop collar on the tail end and poor MkII paid the ultimate price. MkIII has since been threaded and the the retaining bands removed. The next stop collar will instead be brazed to a short tube that slips over the battery tube before being brazed in place. That will prevent another unfortunate mischance. At the other end I used a carbide Dremel bit to cut the shelf out of the switch pill. Then I reamed it to one continuous ID and brazed a thin tube to fit inside. The switch will actually go in the small tube with contacts at either end and slide into the larger threaded piece.
Tail stop

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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If you say it is I am not going to argue. It would be a lot easier to do MK 2 in the first place and just bypass MK 1. Silly

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Rufusbduck
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It would certainly have saved me the time I spent ruining the MkII tube. I’ve brazed and threaded 3 tubes now and wasted yet another day on the stop. With all that’s left to do these set backs are frustrating. the 2 lb single jack I mean shower floor really did a number on MkII but it was a necessary catharsis.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

TexasLumens
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Rufus, you make me tired just looking at all the work!!! Facepalm Tenacious would not cover your attitude toward making a light.

I’ll just sit here and try to recover slowly until the next highly anticipated update. !!! TL

Texas Lumens Website… http://www.texaslumens.com

WE LIVE IN THE LAND OF THE FREE ONLY BECAUSE OF THE BRAVE!

Rufusbduck
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I hope this isn’t a let down then. To make the stop collar I squared up a tube end on some sandpaper. And brazed it to a brass disc. Here it is next to the battery tube. Sooner or later I’ll need to cut some threads on the copper pill stock I brazed up way back when. Some of it will be used for the emitter pill and some for the tail cap. To hold the stock while I crank the die I brazed up this piece that I can solder the stock to. Next

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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Good luck. Sad

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

Rufusbduck
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34 days left, I might still make it.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

CRX
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Keep at it mate.

MRsDNF
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Rufusbduck wrote:
34 days left, I might still make it.

Make it or make it? I reckon you’ll do both. Smile

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

TexasLumens
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Keep going Rufus! I figure next you will be refining your own brass / copper from ore!! Silly I am changing your name to ToughRufus!!

Looking forward to the next update. TL

Texas Lumens Website… http://www.texaslumens.com

WE LIVE IN THE LAND OF THE FREE ONLY BECAUSE OF THE BRAVE!

Rufusbduck
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Having trouble with pics. Those will be part of the switch set up. The following are the making of a lip on one piece and a shelf for the switch to rest on.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

Rufusbduck
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I think I exceeded the post length and the pics wouldn’t laid. To continue with yet more. Here is the sequence on the copper pill stock. The biggest one is the pill, the medium one goes in the tail cap, and the thin one is the driver retainer.
Led pill

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

MRsDNF
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I love that die stock. Thumbs Up

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

MtnDon
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Wow! Good work!

DavidEF
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MtnDon wrote:
Wow! Good work!

Understatement of the year? Wink

It’s guys like RBD and MRsDNF and CRX (and several others) who make the BLF contest interesting to watch every year. The attention to detail is outrageous!

The Cycle of Goodness: “No one prospers without rendering benefit to others”
- The YKK Philosophy

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^

+1

Incredible craftsmanship and artistry in this build.

Rufusbduck
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Thanks guys. Compared to what Hoop can do this is really low grade work, the threads feel like they have teeth they are so rough, similar to pipe thread from the hardware store. I might try dressing the leading edges of the cutting teeth at some point. Hand work isn’t supposed to be clean and precise but it’s irritating to fall short of expectations. that probably shows a lack of humility but I get paid to worry over details and unlike my professional jobs the more I work on these parts the uglier they get. That being the case I’ll just have to avoid over working the finished assemblies. The problem is that to imitate what can be done on a lathe I have to build up layer upon layer, each one adding brazing alloy and requiring filing/sanding to fit the next one. The two button pieces were thin sheet brass formed to the same curve as the battery tube with nesting tubing sanded to the same curve before cutting ~5 mm off to braze. In all, there are nine separate pieces of brass to make the thumb switch module and eight more(including two of copper) in the tail cap. When it’s all done I’ll count up all the rest but “bucket Of parts” was a pretty apt description. I seem to use the drill press enough that I should change my screen name to MrSdp but there’s a lot more time hand working small parts or sanding things ~round /~square.

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

TexasLumens
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Rufus, Copper + a Die shouldn’t = threads anyway!! Beer That is like threading bubble gum with a golf club. You did danged good. I like the way you used the die as a holding jig!!! I would never EVER have thought of that.

On that copper a scotch brite pad and your drill press will smooth those threads some. I call them “Scrubbies” in my shop. If you don’t have one, PM me your mailing address and I’ll mail you a couple. They are good for a lot of things. I sure enjoy seeing your efforts and ingenuity. Thank you for the effort it takes to show us all that work. Thumbs Up

TL

Texas Lumens Website… http://www.texaslumens.com

WE LIVE IN THE LAND OF THE FREE ONLY BECAUSE OF THE BRAVE!

Rufusbduck
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Thanks, we have them and I’ll try it. If it works on Revere Ware then why not? For the record, that’s an 18” pipe wrench I used to tee off. Wink

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

Scott

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As well as Scotch Brite I remember OL (at least I seem to remember) using steel wool, the fine stuff for cleaning up threads. I agree with you RBD about Hoop. What he does with copper is a work of art but yours is also just worked in opposite ways. Thumbs Up

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

TexasLumens
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MRsDNF wrote:
As well as Scotch Brite I remember OL (at least I seem to remember) using steel wool, the fine stuff for cleaning up threads. I agree with you RBD about Hoop. What he does with copper is a work of art but yours is also just worked in opposite ways. Thumbs Up

I think the steel wool is good… but remember…. if it is a copper part that you are going to patina, don’t use the steel wool. Boy did I get in trouble with that one time!! Whew! I did a copper light for a customer and he wanted a patina on the copper… an ugly green mess in my opinion…. but I had used some steel wool for a fine satin look first. I have always thought the steel left a coating of some kind on the copper… the patina was blotchy and a real mess. Even after being in a sonic cleaner and then steam cleaned. When I re-finished the copper with a scrubbie, the problem went away. That only cost me a full day!! Sick

TL

Texas Lumens Website… http://www.texaslumens.com

WE LIVE IN THE LAND OF THE FREE ONLY BECAUSE OF THE BRAVE!

MRsDNF
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Thanks for the update TL. It may well of been aluminium the steel wool was used on.

 

djozz quotes, "it came with chinese lettering that is chinese to me".

                      "My man mousehole needs one too"

old4570 said "I'm not an expert , so don't suffer from any such technical restrictions".

Old-Lumens. Highly admired and cherished member of Budget Light Forum. 11.5.2011 - 20.12.16. RIP.

 

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