Projects from the shop, a window into another guy's obsession

[David Borden]

Charles, thank you! Really look forward to seeing how it cuts and looks... Will post some pics once I have something to show.

Reiver, thank you as well... Color is Salmon Metallic and I think its code 036.

David

[turbobrat930]

David... LOVE the fabrication!!! The machining, the turning on the lathe, the CAd... AWE-SOME!!!!!

[Charles Freeborn]

Originally Posted by David Borden

Charles, thank you! Really look forward to seeing how it cuts and looks... Will post some pics once I have something to show.

Reiver, thank you as well... Color is Salmon Metallic and I think its code 036.

David

My pleasure. That size waste usually goes into my woodstove... BTW, try the foam backed abrasive made by Norton. They're great for final sanding on a lathe - soft metals too.
https://www.amazon.com/Norton-02653-Contour-Sanding-Sponge/dp/B000KKPE74/ref=sr_1_fkmr1_3?ie=UTF8&qid=1465919630&sr=8-3-fkmr1&keywords=norton+3x+foam+sanding+pads

On wood go all the way to 320 grit, then seal and finish. For figured wood (like the Walnut) I use Seal Coat by Zinser:
1 Quart Zinsser Bullseye SealCoat - Rockler Woodworking Tools
Then Gel Poly:
General Finishes Gel Topcoat - Rockler Woodworking Tools

You can skip the sealer step, but it will take a few to several more coats of topcoat to get a build.

BTW, beautiful part of the state you're in. I lived in Oakland for 25 yrs before moving up here. Used to take drives all through the foothills for many years.

[al lkosmal]

David,
Nice work.

regards,
al

[David Borden]

Thanks you, appreciate the comments!

Charles, I got the wood, THANK YOU! Very nice looking pieces... Hoping I will be able to take a stab at it within a week. Thank you for the suggestions on finishing. Do you know if they make that same stuff with UV protection? Some of my friends cars are open including a couple of mine.

Spent a fair amount of time making soft jaws for the 3 jaw chuck to make the chuck run more concentric. Should have them done tomorrow.

David

[David Borden]

A ton of time has been spent in the shop the last week or so with some great progress on the shift knob project. I've become a bit obsessed with it.

What has been a great deal of fun, is many of my friends have been providing input on design and giving me wood to try, including Charles! It's been a bit of a community project.

First line of business was to create some soft jaws on the mill. As mentioned before, I was working on soft jaws for my 3 jaw chuck. This type of chuck is not very concentric, but if you make soft jaws, you can true them up once installed.



They almost got the best of me… These things took the better part of a couple days to design and machine to the point where I was happy with them.



In the end it was worth the effort as I was able to reduce the chuck runout from about .004” to .0005 - .001” which should be good enough.



Another beast lurks in the garage… This car took about 4 years and a couple thousand hours to build. What's another 10 for a shift knob?



My friend Brad has been providing some good feedback. He is a mechanical engineer so told him to design up a dream knob for his 68 Camaro project and since the cobra was in the shop, it gave me a guinee pig for the project

Making it an assembly so that each part is referenced to another, you can make them nearly a perfect match so they feel smooth in the hand.



Each piece separately.

[David Borden]

Insert off the machine.



Some Walnut my friend Tracy gave me chucked up and ready to try.



The wood just slipped onto the insert before finishing



How about a quick finish on it..



Overall it turned out great.

My friend Tracy who is an avid wood worker started making some sample knobs at home to get ideas for combining different woods and finishes… Will post some pics in the next few days.

Charles, I made my first knob with the burl and will post some picture of it soon! The wood is gorgeous in the sun…

As always, let me know your thoughts...

[David Borden]

Charles… so thanks again for the wood! Finally got to the point of feeling confident enough I wouldn't screw those beautiful pieces of wood up and took a shot at it.



Chucked up the worst piece and did an initial turn on it. It really cut well! Took about 10 minutes to sand it and then put a couple coats of urethane and this is how it turned out… I cant believe how it pops in the sun.





Im working on a modified version for the 911 now.

David

[David Borden]

Many hours have been spent in the shop over the last few weeks playing with the shift knob project. One of the issues is figuring out how to hold the insert for the air cooled Porsche after its machined.

Came up with something for a split arbor that would be a slip fit but made in 2 tapered pieces.



By making a little slip fit collar, I am able to use the same arbor for holding .750" ID parts.



Hey Charles.... check this out!

Using the wood you sent me, I re-shaped the 911 gear shift knob and shortened the insert as well. It now measures 1.77" at its widest part and feels wonderful in the hand.

Its hard to believe that this:


Now looks like this:




A good friend asked if I could make him a shift knob for his car out of African Black wood. He purchased a blank of wood and gave it to me to experiment. This is the same shape of the Burl wood above.

Its really incredible looking. At first look, it looks truly black... until direct light or sun hits it and it has a dark grain that just glows. These parts have no stain on them, just an exterior clear urethane.




Here is a shot of these two along with another cool one I made out of a laminated piece a good friend made for me. He's a really talended wood worker.



David

[tdw28210]

Sweet

[Charles Freeborn]

Outstanding!

[David Borden]

Thanks guys!

Charles, how do you want yours? As promised, I am going to make you one for sending me the wood.

I can use a piece of what you sent me as I have one left, or if you want to send me anything else just for it thats cool as well. I can get it to you finished or I can send you the two parts and you can do whatever you do as well. Im still a complete noob at finishing wood.

What do you guys think of the insert? Should I make any changes to it? What about the shape of the knob?

[ajwans]

This is fantastic, love it. Can't wait to see what you'll come up with next.

andy

[al lkosmal]

David,
Excellent functional art.

regards,
al

[michael lang]

David, I think this is really cool. Based on the pictures, you are very passionate about being a perfectionist. It definitely shows in your work.

[GeorgeM]

My old '74 was Salmon Metallic...... love it!!

[CountD]

Love that '74. Right on.

[David Borden]

Thanks for the comments, they are definitely appreciated.

George, nice looking 74... Its interesting how the color can look so different depending on the light.

A friend of mine just handed me a big chunk of Ebony to turn. Will post some pics once I have something worth showing. I don't think I've ever seen the wood before, so its going to be fun to play with.

David

[Charles Freeborn]

I'll cut some more material for you then you can choose which for me. Makers choice! I have some really cool Eucalyptus that came from a vineyard in Napa. Wild figure. What are the rough dimensions of a blank?

[GeorgeM]

Congrats on PCA E-brake photo of the month for June! Great pic!