Category: Other projects

Metal roundel for the vice

Builder: Wolfgang Lundelius

Creation time of the model: approx. 8 hours

Total cost: approx. 50€

Level of difficulty: Advanced

Metalworking tool with two rollers, a cylinder and a rod. The tool is fixed in a vice.

The project

In this customer project, a metal rounder was manufactured for a vice with a jaw width of 150 mm. An important requirement was that the metal rounder should also be able to round thicker material (e.g. 5 mm) effortlessly and that the radius should also be very small.

Material used:

8 x ball bearing type: 6204 2RS C3 for shaft (20 mm), outside 47 mm, width 14 mm
2 x ball bearing 6904-2RS Z2 for shaft (20 mm), outside 37 mm x 9 mm
1 x pipe section 1 ½" x 3.2 mm and length approx. 100 mm
1 x short tube piece, 37 mm inside (for the small bearings)
1 x axle shaft ø 20 mm, length approx. 250 mm
1 x flat steel 30 x 25 x approx. 500 mm
1 x round material ø 10 mm
4 x sliding bush 10 mm inside, 12 mm outside
6 x copper ring as washers for 20 mm shaft
M8 screws, M6 grub screws, some washers

Tool used

Step 1

Make a sketch

A sketch was first created for the desired dimensions of the base support.

Technical drawing: Four rectangular metal rods on top of each other, with drill holes and dimensions. Illustration of copper plain bearings.

Step 2

Drill holes and cut threads

First, the flat material was divided into two equal halves and milled flat from the left and right. The centre of each flat material was then determined using the edge finder and the holes were centred according to the sketch using the centring drill. Next, the holes for the threaded screws were pre-drilled as through holes (8 mm) and the diameters to the axle shaft were milled in several steps using milling cutters. The holes were then deburred with the countersink. In order to be able to drill the guides, 10 mm through-holes were then produced on the part with the four axle holes. In the next step, the M6 threads were cut (these will be used later for the grub screws) to fasten the guides.

Two metal rails parallel to each other, each with three holes. One metal rail is vertical on the left. In the foreground a texture with the number "1".

Two horizontal metal blocks connected by two vertical rods. The upper block has one hole in the centre, the lower block has four.

Two rectangular metal blocks, one with two large holes and one small one, next to three metal rods.

Step 3

Manufacture the transport roller

Firstly, the axle shafts were sawn and turned flat. They were then centred and completely drilled with core holes for M8 threads. The holes were then countersunk and finally the thread was cut.

The length of the axle shafts depends on the height of the material to be rounded. In this example, the axle shafts are 80 mm long.

In the next step, the ½" tube was sawn and turned flat. The second (slightly smaller) tube was turned inside and out for the small ball bearings so that it fits pressed into the ½" tube. This construction later serves as a support for the larger bearings, which are inserted into the shaft. The small and large tubes were then welded together and turned out again. Finally, a hole was drilled in the side of the finished part for the tommy bar.