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Slim LDC

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WobblyHand:
Oh, this kicked my butt for a while, but I think it's pretty good for a first pass.  I'm just glad I got the threads to mate correctly!  Not that easy when nothing is standard.  Still needs a little clean up, but it worked out ok.  Can't say I'd ever consider this for making a bunch of these, it was more if I could make this at all.

Threaded and grooved the inside of the CF tubing.  Had to grind an existing tool I had made for the groove.  The tool needed more clearance due to the 22mm ID.  Then I reversed threaded it using a left hand threading tool.  (Right hand thread  tool going towards the tailstock, lathe in reverse.) 

The cap was made of 1" aluminum, and turned down to 25mm, the OD of the CF tube.  Then I turned the thread area to 23.2mm, hoping my calculations were right.  I made a 1mm thread groove - which wasn't quite enough.  And I single point threaded it towards the chuck.  The thread pitch was 0.7mm and the threaded area is 3mm long.  Then I parted off the piece and cleaned it up.  Moment of truth came when the pieces threaded together!

Next, to cut the CF to length and to fit and glue the LDC in place.

subscriber:
Looks like a tricky job.

WobblyHand:
Standard machining.  Only tricky figuring it out the first time.  Had to fix a minor blunder due to a brain fart while machining as well.  Should I make another one, it should go easier. 

WobblyHand:
Spoke too soon, minor issue which I can't quite figure out.  I have a gap between the cap and the CF tube.  Not sure where it is coming from, just can't determine the interference point.  It's about 0.015".  I have sufficient thread depth in the tube, and a thread groove past the threads.  Can't see any boogers on the cap that are big enough to matter (under a microscope).  I even took off 0.4mm of the cap thread length and I still have the gap.  I figure I will fill that area with adhesive.

Even with that, booboo it came out ok.  If I were to make another one, the barrel adapter would be made out of 1" stock, since I'd rather the adapter be flush with the CF tube.  Considering this was organically designed, instead from the get go, it's still pretty decent.  Looks a bit nicer with the CF tube.

Not going to lie, the machining was interesting to figure out, because I've never machined a piece like the aluminum end cap before.  It was even more interesting to attempt to fix the booboos.  When there's only 3mm of stock the piece is hard to hold!  I used a 25mm ER40 collet that had a 25mm piece of stock in it.  It was the same piece of stock that I had machined the end cap from.  So the diameter was exactly the same.  I pushed in 2mm of the endcap into the collet plus the 25mm piece of stock and prayed that it would hold.  It did.  If it wouldn't hold on, I would have super glued the two pieces of stock together at their face, while positioned in the collet.  Think it would have been easier with 5C collets, but I don't have a 5C chuck, so I had to make do with my ER40/identical slug diameter trick.

subscriber:
Debugging is fun.  Not :)

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