Andy J Posted July 29, 2022 Author Share Posted July 29, 2022 Thanks Chris but will wait to see if the ones I have ordered are suitable. Should have plenty of spares if anyone else needs some as they came in packs of 25. Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 2, 2022 Author Share Posted August 2, 2022 Well would not recommend the washers from Macc Models as the 6.5mm ID is a sloppy fit to a 1/4" plug. Quote Link to comment Share on other sites More sharing options...
David Ovenden Posted August 2, 2022 Share Posted August 2, 2022 Probably little help to you at this moment but I have just measured the washer from a brand new unused OS F plug. O/D 8.3mm, I/D 6.4mm, thickness 0.7mm. 6.4mm is pretty much 1/4". Washers are often made to be an easy sliding fit over a bolt. So a nominal 1/4" washer is likely to be more than 6.4mm I/D. Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 2, 2022 Author Share Posted August 2, 2022 Well just purchased some 10mm copper rod with the intent to see if I can make some washers on my lathe. Quote Link to comment Share on other sites More sharing options...
Paul De Tourtoulon Posted August 3, 2022 Share Posted August 3, 2022 8 hours ago, Andy Joyce said: Well just purchased some 10mm copper rod with the intent to see if I can make some washers on my lathe. So have you bought a lath and milling machine to make them ?.🤣 Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 3, 2022 Author Share Posted August 3, 2022 Bought the lathe probably 18 months ago thinking it would be handy. So far have put it to little use other than making an extended dome prop nut so making some washers will at least see it being used. Possible that I have the wrong cutting tools for turning copper so will have to consult my friend who is more experienced as to what speeds and cutter to use. Quote Link to comment Share on other sites More sharing options...
alan p Posted August 3, 2022 Share Posted August 3, 2022 Sharp HHS parting off tool should be fine, its the lubricant to prevent the cooper cold welding to the tooling and drill you need to check on.  Been a long time since I m/c'd copper so memory is not so good, should think suds or oil base should do it. Quote Link to comment Share on other sites More sharing options...
Don Fry Posted August 3, 2022 Share Posted August 3, 2022 (edited) You will need a blowtorch as well. Heat the workhardened washers carefully, and they go red. Too much, they melt. And toss washers into cold water. They are then soft and deformable. I reckon to make them, rod in the chuck, drill the hole deep enough for a dozen, turn the outside down to diameter, and make/cut each washer from the block with a parting tool. Then soften  as above. Nothing special needed, an old hacksaw will serve as a parting tool. Cutting speed such that the tool does not dig in. Edited August 3, 2022 by Don Fry Quote Link to comment Share on other sites More sharing options...
Paul De Tourtoulon Posted August 3, 2022 Share Posted August 3, 2022 You will also need a bench grinder for sharpening the lath tools and an electronic Vernier caliper for measuring and of course a box to store them, in😉, Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 3, 2022 Author Share Posted August 3, 2022 All tools present and correct. Any advice as to cutting speed? Quote Link to comment Share on other sites More sharing options...
Don Fry Posted August 3, 2022 Share Posted August 3, 2022 Nothing special about copper. Assuming the drill bit is a normal useable drill. Drill the centre hole winding the tailstock in at a nice steady fashion, not on piece rates here…… face off the copper rod, then reduce the diameter for a dozen washers and a dozen cuts, then cut off the washers with the parting tool. Slow or fast as you like, but too fast, it might go wrong, get a cutting speed where the lathe does not sound strained. One trick, you can face off the tool marks by rubbing them, finger will do, on a sanding block, wet and dry. Then make them soft again. Quote Link to comment Share on other sites More sharing options...
jeff2wings Posted August 3, 2022 Share Posted August 3, 2022 You would be better off making a die/punch and copper sheet,after all that's how washers are made ! Quote Link to comment Share on other sites More sharing options...
Don Fry Posted August 3, 2022 Share Posted August 3, 2022 I’ve just reread your post. I assume you have a manual lathe, and am not planning using power feed lathes. If so, beyond my skill set. The copper in your rod will be soft. it cuts very easily. It’s not much harder than nylon, and even if your cutting tools are not great, will cut copper. As I said earlier, an old hacksaw blade will part copper. Another trick, after drilling the centre hole, block it with dowel, or a nylon bolt. Then as the metal starts to break away, it’s held in place until all the metal is cut.  watch your fingers, the scarf is really sharp. Looking on the bright side, copper is very poisonous to all life forms, and the cuts don’t go manky. Quote Link to comment Share on other sites More sharing options...
Don Fry Posted August 3, 2022 Share Posted August 3, 2022 Jeff is quite right. But you need some copper sheet. And a press if you don’t want deformed washers. Again, not my skill set. Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 8, 2022 Author Share Posted August 8, 2022 Well making washers is not easy! Took me three attempts to get 1 good washer. As Don states the hole need to be plugged when parting off. Quote Link to comment Share on other sites More sharing options...
Don Fry Posted August 8, 2022 Share Posted August 8, 2022 Arrrr, but the point is you did, and it did not have to come round the world. It would have been easy just to accept the offer of a couple in the post. You showed the obstinate bloody minded attitude to life that any respectable practitioner of this game possesses. I electronically shake your hand. Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 8, 2022 Author Share Posted August 8, 2022 Did have to destroy one perfectly good 10mm copper bar in the process though Don. 1 1 Quote Link to comment Share on other sites More sharing options...
David Ovenden Posted August 8, 2022 Share Posted August 8, 2022 It's no help to you Andy, but in a bizarre twist of fate, today I found a brand new glowplug washer on the floor. I lost it months ago and after I dropped it and then just couldn't find it. During a general "tidying up" today (when I wasn't looking for it) I found it. Shame I'm in France not round the corner from you. C'est la vie! Quote Link to comment Share on other sites More sharing options...
Don Fry Posted August 8, 2022 Share Posted August 8, 2022 3 hours ago, Andy Joyce said: Did have to destroy one perfectly good 10mm copper bar in the process though Don. Andy, I love you. A bit of copper bar, destroyed. I am a bit lost here, man wanted a washer, had a lathe . No press. Got a washer. So three mistakes, 2 mm to 3 mm a mistake, that’s a 10 mm bar destroyed. Bet after the learning curve, it’s one washer, one cut. What is the use of copper bar. 10 mm. 440,000V 3 phase? Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 8, 2022 Author Share Posted August 8, 2022 1 hour ago, David Ovenden said: Shame I'm in France not round the corner from you. C'est la vie! Well if my plans had worked out in latter life I too would be living in France David. Although I visited Paris on multiple occasions for work my French was never good enough to permit moving there on a permanet basis. Plus the stress of my last house move 14 years ago put me off moving again after retirement. Quote Link to comment Share on other sites More sharing options...
Paul De Tourtoulon Posted August 9, 2022 Share Posted August 9, 2022 10 hours ago, David Ovenden said: It's no help to you Andy, but in a bizarre twist of fate, today I found a brand new glowplug washer on the floor. I lost it months ago and after I dropped it and then just couldn't find it. During a general "tidying up" today (when I wasn't looking for it) I found it. Shame I'm in France not round the corner from you. C'est la vie! I offered to post him a couple but fallen on deaf ears, still maybe worth putting your 'lost washer' on ebay David.😉 Quote Link to comment Share on other sites More sharing options...
Andy J Posted August 9, 2022 Author Share Posted August 9, 2022 Well if you list them on ebay you can declare them as a rare item. 1 Quote Link to comment Share on other sites More sharing options...
Paul De Tourtoulon Posted August 9, 2022 Share Posted August 9, 2022 57 minutes ago, Andy Joyce said: Well if you list them on ebay you can declare them as a rare item. "collector",,,🤣 1 Quote Link to comment Share on other sites More sharing options...
Paul De Tourtoulon Posted August 9, 2022 Share Posted August 9, 2022 (edited) Looking at all the interest and rarity of this unavailable product i decided to do a 'tuto' on making one. First one to measure, I seemed to have found one,,,🥳 Then you need Safety Goggles a lathe with it's accessories, a small rat tailed file and a vernier gauge for finishing some fine emery cloth.  Some metal, here aluminium, and copper, I settled for the 6mm OD copper tube,  a 6mm drill and hammer.  Start by putting on your safety Goggles.  The drill was inserted it the copper tube and hammered on the outside to open it up to the right size here ID of 6.3mm. then inserted into the lathe to be faced off and with the outside diameter checked, i parted it off with a fine and sharp parting tool the 6mm drill is inserted to support the tube while parting. then both surfaces cleaned up with the emery cloth, the rat tailed file to clean off the swarf from the inside then finally annealed, heated to cherry red and quenched in water.  In the last image you can see that I have successfully achieved my mission.  Any questions please feel free to ask.  If the Moderators find this post too silly no offence will be taken if it is deleted.😇 Edited August 9, 2022 by Paul De Tourtoulon Ps; 20 minutes work 1 Quote Link to comment Share on other sites More sharing options...
Masher Posted August 9, 2022 Share Posted August 9, 2022 All very well but how much testing have you done? How do these hold up over various temperature and fuel conditions? What about high compression situations? Not being funny but I don't think you have fully understood this very complex requirement 2 Quote Link to comment Share on other sites More sharing options...
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