First all, thanks for stopping by this thread! i am imagining people here on blf who have machining or home shop fabricating experience may find this mildly interesting or be able to lend some help. to anyone else, this thread may be boring and pointless. sorry in advance. Im just at a loss and aggravated.
Im trying to start making/fabricating my own “ring style” pocket clips for some of my 26650 lights, 21700 lights, etc (think fw3a deep carry clip, kr4 deep carry clip). The type of clip that attaches by removing the tailcap, placing the ring of the clip over the tail threads, and installing the tailcap to secure the clip.
I am using somewhat basic power tools (band saw, drill press, power disc/belt sander) as i don’t have a lathe, milling machine, plasma cutter, or any access to cnc enabled machines or cutters (unfortunately).
I started by drawing out the measurements onto 18 gauge plate steel from the box store (18”x24” piece of mild steel, i believe). I used a compass and drew the inner and out rings, measured the length i would need the clip to be including all of the bends for deep carry but no return (i am not looking for the clip to return like what is needed for baseball cap attachment).
Everything was going great until i started cutting the 18 gauge steel. First off removing the material for the inner diameter of the “ring”, the part of the clip that will go around the tail threads, was almost impossible. Basically i need to take out a 31 mm diameter section of 18 gauge steel with a small drill press and my largest bit is a 1/2” drill bit… i just got no where. I have more bandsaw blades on order (3/8” 18 tpi, 1/4” 15tpi) on order as my bandsaw is new and i have never used one before and i have a 8 tpi wood cutting blade. it didnt work! :person_facepalming: i’m pretty new to this stuff.
Does anyone have any suggestions? Is it easier to try and reach out to a machine shop? (i doubt they would help with such a small order, i will only need a few of each and all sizes will be slightly different for each light). is there some inexpensive plasma cutter i can buy or try ( i know there probably is not a cheap one!). I imagine a plasma cutter or something like that would be much more feasible for cutting the steel. I DO have a welder, a cheap harbor freight MIG Style(i think MIG? Its not TIG i know that). I want to learnt to weld so i bought one, i’ve watched a ton of videos, just havent had the time to tear into learning how to use the welder yet. Can this be used in any way? sorry if this is a stupid question.
I really want to fabricate these clips if i can myself with the tools i have.
Also, i am pretty sure i have the bending of the clip down (once i can get it efficiently cut!), because i have bent steel before with a hammer and my 6” vice. I also may buy a small steel Brake for bending them too.
I desperately need some suggestions or help, and i know there are members on here who are geniuses in their own right!
i don’t know where else to ask these basic questions, so here i am.
Thanks again.