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ligito
02-24-2009, 12:46 PM
I want to make some clamps for switches, lights etc.
I'll make them out of billet aluminum.
After drilling and tapping the clamp and drilling the main hole, how should I separate the two parts?

Bandsaw?
Small diameter end mill?






http://s267.photobucket.com/albums/ii319/ligito/

Carl_In_NH
02-24-2009, 12:48 PM
Slitting saw on an arbor.

ligito
02-24-2009, 12:54 PM
I only have a horizontal bandsaw, Cold cutting saw and a mill/drill.

steverice
02-24-2009, 12:57 PM
To make a housing I would put two peices together, then bore a hole a couple though small for squish.

softtail
02-24-2009, 01:17 PM
Slitting saw in arbor, in mill.

kendall
02-24-2009, 02:04 PM
Agree slitting saw after boring, kerf takes care of any 'squish' you need.

Make sure the flanges are heavy enough for your use, bike fan here and I've found that many of them tend to curve and not hold.

Ken.

dp
02-24-2009, 02:10 PM
Make them from two parts. Shim between them for drilling.

Evan
02-24-2009, 03:06 PM
Don't bother making them. Go to your local bicycle shop and ask them for some junk aluminum handlebar stems. Modify as required.

Like this one I use to hold the flashlight:

http://metalshopborealis.ca/pics5/hbar.jpg

dockrat
02-24-2009, 03:18 PM
I make clamps for various motorcycle handlebar parts. I use my vertical bandsaw to make the cut after all other machining, threading, and tapping is done.

ligito
02-24-2009, 04:22 PM
I make clamps for various motorcycle handlebar parts. I use my vertical bandsaw to make the cut after all other machining, threading, and tapping is done.

I'm making these for ATV's and motorcycles, so they need to be stout enough to handle vibration. (not for Harley's).

ERBenoit
02-24-2009, 05:19 PM
I want to make some clamps for switches, lights etc.
I'll make them out of billet aluminum.

If you're selling them, make sure you get top dollar. Billet aluminum is special stuff. :rolleyes:

steverice
02-24-2009, 05:26 PM
If you are selling them don't use a band saw, that looks really cheap.

ligito
02-24-2009, 07:39 PM
I'm just using them for friends and self.

A.K. Boomer
02-24-2009, 08:06 PM
Make them from two parts. Shim between them for drilling.


I like DP's method above, I have to add for ultimate strength here's what I do,

Mill flats out on both half pieces BUT unevenly -- on one piece and its mate mill so they will connect and be flush -- on the other sides mill an extra .020" on both mates --- then install .040" feeler gauge and bolt pieces together with pre-drilled and tapped holes, Now bore to size of bars, When installing on bars mount flush mounts together on top of bars and torque -- then tighten up bottom bolt to bring in pieces of clearance -- this is how Honda has done it for decades , they and many others also utilize this method on the front axle clamping system,
Note; You can avoid the entire feeler gauge issue and just mill one piece .020" lower on one side and do the same to the other --- bolt them together unmatched ( a high to a low and a low to a high) so they will be level - now bore -- then re-flip for install... ---- Use this method only if the entire piece is indicated otherwise your halves will not line-up and your clamp will be weak and junk.
Nuther Note; this is great for bicycling stems and stuff that you dont want moving on you, for things like clutch and brake levers remember to leave the bottom bolt only as tight as operation dictates -- its good to leave stuff like this just a little snug as your levers will rotate in crashes instead of break -- This is the first thing you do when you get ahold of a new bike;)

Evan
02-24-2009, 08:07 PM
A band saw in good order will make a cut that you can't tell from a slitting saw unless you are a machinist. Maybe not then either.

Slit with band saw.

http://metalshopborealis.ca/pics/bear3.JPG


http://metalshopborealis.ca/pics/collet1.jpg