Making Lever Caps and Lever Cap Screws in the Backyard

[Derek Cohen (Perth Oz)]

As mentioned in my recent post on building a jointer, here is a link to an article I have completed on building lever caps and cap screws with basic tools.

http://www.wkfinetools.com/contrib/dCohen/leverCap/lCap1.asp

I hope this is useful.

Regards from Perth

Derek

 

[ByronBlack]

Derek, thanks for posting that, I just read the guides and step-by-step instructions and staggered at how easy it all looks. I know next to nothing about metal-work, but this looks one project I could handle. Definitly gives me something to think about for future plane projects.

Cheers Del!

 

[JesseM]

Great tutorial Derek! Did you just center the bolt in the cap by eye? I think it woulda been cool if you could've somehow left the the coin intact. One other question. You refer to the stuff you used to make the cap iron as brass, but it looks like copper. Is it a different alloy? I've never seen it that color before.

BTW I've looked for brass bolts that large before at the hardware store and the biggest I've come up with is 1/4" with a philips head. Prolly large enough but I think your right about the specialty shop.

 

[Evergreen]

Derek

Really helpful tutorial, thanks. I need to know more about basic metalwork - it's a blind spot for me.

Regards.

 

[Derek Cohen (Perth Oz)]

Did you just center the bolt in the cap by eye? I think it woulda been cool if you could've somehow left the the coin intact.

Hi Jesse

Yes, the coin was centred by eye. Masking tape will help centre it. On the cap with the black ring, the bolt head was made smaller so that it could fit within the ring, and then filled with coloured epoxy. Again, this was centred by eye.

One other question. You refer to the stuff you used to make the cap iron as brass, but it looks like copper. Is it a different alloy? I've never seen it that color before.

It is phosphor bronze. An incredibly hard metal! I believe it is used for bearings and screws, etc. It is quite striking against the Jarrah.

http://www.metalreference.com/CU_510.html

Regards from Perth

Derek

 

[JesseM]

It is phosphor bronze. An incredibly hard metal! I believe it is used for bearings and screws, etc. It is quite striking against the Jarrah.

http://www.metalreference.com/CU_510.html

Regards from Perth
Derek

Thanks. Yes I agree it does look quite nice.

 

[woodbloke]

Derek - that's a great tutorial, I'm going to have a go at making a cap iron and bolt like the one's you've done and see what I can do in the plane making department - Rob

 

[CONGER]

Inspiring... as with all Dereks contributions.

-ger-... who is envious of the great woods from Auz... Huon Pine... Tasmanian Myrtle... and of course Jarrah and Jarrah and Jarrah!

 

[promhandicam]

thanks for posting the link to your tutorial derek. I've been thinking of making a scraper holder and think that I can apply some of your methods to that. If / when I do make one I'll post up the results.

Thanks, Steve

 

[bugbear]

Derek - I have sometimes "had cause" to rethread a bolt;

http://www.geocities.com/plybench/tour. ... ey_threads

When I do so, I hold the die upright in the vice, and use a brace/screwdriver to drive the workpiece.

It's really easy to do the 3/4 turn forward, 1/4 turn back this way.

I always fear the risk of slipping in the head when using a hand screwdriver, especially in a awkward position.

BugBear