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Binary Rock

  1. 2012

2012-09-21 - Bryan Flashlight

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  • Cutting stock for the bezel

    Cutting stock for the bezel

  • Faced flat, turning outside diameter

    Faced flat, turning outside diameter

  • Turned down to largest outside dimension

    Turned down to largest outside dimension

  • Ridge for hex flats cut

    Ridge for hex flats cut

  • Two decorative grooves cut

    Two decorative grooves cut

  • Chamfer cut

    Chamfer cut

  • Center drilling for removal of center material

    Center drilling for removal of center material

  • Drilling through with a 3/8" drill

    Drilling through with a 3/8" drill

  • Then again with a 5/8" drill

    Then again with a 5/8" drill

  • Boring out to the various internal diameters needed

    Boring out to the various internal diameters needed

  • More boring

    More boring

  • Internal boring done

    Internal boring done

  • Cutting internal threads for mating with light engine and battery tube

    Cutting internal threads for mating with light engine and battery tube

  • Parting off the piece

    Parting off the piece

  • Progress so far

    Progress so far

  • Chucking it back up by the tail end

    Chucking it back up by the tail end

  • Facing flat

    Facing flat

  • Setting angle for front chamfers

    Setting angle for front chamfers

  • Outside chamfer cut

    Outside chamfer cut

  • Inside chamfer cut

    Inside chamfer cut

  • Transferred over to rotary table on mill, cutting flats

    Transferred over to rotary table on mill, cutting flats

  • Cutting crenellations

    Cutting crenellations

  • Cutting round grooves with ball end mill

    Cutting round grooves with ball end mill

  • Gavin vacuums up the swarf (he did some of the cuts too but I was too busy guiding him to take pictures)

    Gavin vacuums up the swarf (he did some of the cuts too but I was too busy guiding him to take pictures)

  • Bezel done

    Bezel done

  • Chucking up stock for the light engine

    Chucking up stock for the light engine

  • Turned down diameter for threads, now turning the smaller diameter above them

    Turned down diameter for threads, now turning the smaller diameter above them

  • Ready to cut external threads

    Ready to cut external threads

  • Milling out recess for driver board

    Milling out recess for driver board

  • Threads cut, driver board recess cut

    Threads cut, driver board recess cut

  • Ensuring that driver board fits

    Ensuring that driver board fits

  • Parting off

    Parting off

  • Rotary table mounted flat, centering it beneath spindle

    Rotary table mounted flat, centering it beneath spindle

  • Milling holes for wires to run from driver board to LED

    Milling holes for wires to run from driver board to LED

  • Milling channels for wires

    Milling channels for wires

  • Wire holes and channels done

    Wire holes and channels done

  • Drilling holes for LED screws

    Drilling holes for LED screws

  • Tapping holes for LED screws

    Tapping holes for LED screws

  • Light engine flipped around, milling holes for screwing it into bezel with pliers

    Light engine flipped around, milling holes for screwing it into bezel with pliers

  • Light engine done

    Light engine done

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    Cutting internal threads for mating with light engine and battery tube
    Parting off the piece
    Progress so far