Who would be interested in getting 11mm mirror stems?

[markb]

Hey Joe,
Gotcha down, Mark

[Joe K]

Great, thank you, Mark.

[markb]

You guys are going to think I’m totally nuts.  I’ve been working on trying to find someone to do the brazing.  I assumed that each stem would be individually fixtured to locate the clip and then brazed with a torch.  It could be done that way but it will be much, much cheaper to clamp the clip on with a nut and bolt and put them in an oven and braze them all at the same time.  The brazing compound is just a paste that’s smeared on before assembling.  Anyway, I clamped one onto a piece of 11mm rod and wasn’t happy with what I saw.  The outermost ends of the clip hit first and there is a gap near the rod.  Also the radius near the rod should be tighter so the nut doesn’t dig into it.  I thought about going back to the sheet metal guy and see if he could rework them but sometimes those guys just don’t get it.  It’s a pretty subtle thing.  Plus I couldn’t talk to him until Monday so I figured I would tackle making a tool to fix them.  Here’s what I came up with.


Here’s a view where you can see the clip.


Part of the problem was keeping the double D hole lined up.  I added the pin you see in this view.


I used the hydraulic press in our shop to do the work.


Here’s a side view before….


….and after.


Here’s a picture of the clips before (on the left) and after (on the right) reforming.  You can see that the radii are tighter and the end of the clip flare out on the right one to allow the clip to pinch tightly near the rod.


This shows the clips pinched together (left before, right after).  You can see where there is a gap on the left one.


I only did a few to check out the process so I hope to finish them next weekend.  I think it will make a much better product.  Hopefully by next week the stems and nuts will get turned.  I’ve got a minor detail there to figure out too.  After measuring the bent sample I came up with a different straight length than the bender recommended.  So I need to double check that before we starting cutting stems.

[Steve Swan]

Hi Mark, the corrected clip looks fantastic.  Great tool making work !

[kp]

Your a bloody genius 

[markb]

Thanks, but it's not brain science, uh I mean rocket surgery, uh, you know what I mean... 

[Joe K]

Yes, you really are dong a good job with this design.  Good job!

Joe K.

[markb]

The nuts are machined and I had some sample stems made.  I found a different bender and want to triple check them to make sure the length comes out OK before doing them all.  The new guy bends around a mandrel, the other guy bent around a pin so I should get less deformation on the inside of the bend.


I think the nuts turned out pretty good.  I made a few extra in case those of you that are fortunate to have a real 11mm mirror stems, needs a nut.


The stems look good too.  I think the signature thread relief/step looks great.


The plan now is to get the samples bent and if they look good, finish machining the stems.  Then bending, brazing and chrome plating.  Hmmm, that doesn’t sound so bad.

[Wayne]

Looking darn good Mark!

[Joe K]

Yes.  Looks good, Mark.

Joe K.

[Steve Swan]

Bravo !!!!

[kp]

magnifique  .  KP

[kmb69]

Did you make the originals for Honda? Those are looking really good. Keith

[hondasan]

Phenomenal attention to detail. These WILL be worth waiting for. Please keep me o the list for a set.

Chris R.

[markb]

Chris, you are definately on the list.  Thanks for the compliments guys.  

All the stems have been threaded now and they’re out for bending.  As usual they’re saying 2-3 weeks.  Everything takes 2-3 weeks (at least).  Anyway, at least they’re getting there.  Once they’re back from bending the next step is brazing.  I want to be ready so I made up a tool to fixture them.  Here’s a shot without the stem.


Here’s the stem and clip held it place.


It does a nice job of clamping the clip.


I’m not real sure that brazing them in the vertical position is going to be the best so I made it so it can be positioned horizontally too.