Let's Make Robots!

Chemical vise

I have no machine vise, but my project called for one. These pulleys come with a pilot hole. This way you can decide for yourself what kind and size of hole you want in them. I want them tight, 4 mm wide and perfectly perpendicular.

pulley_holes.jpg

So what is a guy with a jig saw and a drill press to do? Right. This.

pulley_ply_vise_0.jpg

It's a piece of ply with a hole in it. The second piece is a lever to grip the teeth of the pulley. However, the lever pushes it askew. The pulley no longer sits perfectly flat and as a result, the hole is crooked and damaged. This is the left pulley in the top photo. You can see it does not sit on the 4mm shaft very tightly. It wobbles too. Shoot! I've got ten of these. Can't hold them in my fingers. The ply-vise even was not strong enough to hold the wheel still. When the drill bit reaches the other side, it "bites" into the aluminium and the wheel starts spinning with the bit.

pulleys_glued.jpg Keep It Simple Rik! Superglue to the rescue!

On a piece of nice flat mdf. Which I can hold safely in my left hand, while operating the drill press with the right hand. But will they ever come loose? Turns out, that is not a problem. The top layer of the mdf will come loose when you pull hard enough. The wheel is not hurt by the abuse, that's why it's called a pulley.

Mind you, superglue on this combination of material is not so super. You need to let is sit in the open air for a little while until the glue becomes sticky. Just like any contact glue. Then push in place and apply pressure.

pulley_drilled.jpg

A bit of extra lube never hurt any drilling.

pulley_pulled.jpg

After pulling them of with plyers, sand off the mdf that's still attached. If you care about that sort of thing. I do, so I did.

pulley_result.jpg

And thusly the chemical vise was invented.

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I used to have a chemical vice... I got my act together when we had kids though...
I must admit: I checked wikipedia just for the spelling!

Now do it again with the pulleys on their side for your setscrew :D

Try using some car bog or something similar to fill the crooked hole. Then you can drill it again with your new skills.

 

 

Is that like Chris' dog? Called "bondo"?

I have some "moudable steel" aka epoxy putty in the fridge. I reckon that would do the trick. And blunt my drill bit.

I was going to suggest a product like that but it can be expensive. Blunting you drill bit can be a good thing with soft metals like aluminium and copper. It stops them from biting into the metal too much.

LOL. Very inventive!

I especially like the way you show a bunch of binary numbers in the upper left corner of the last picture. Artistically subtle.