D5 Hammer Production

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Thorgon

Big Wall climber

Sedro Woolley, WA

Jun 23, 2010 - 01:43pm PT

Theron,

Keep fighting the good fight, Bro!

Can't wait to see pics!
Thor

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Jul 3, 2010 - 01:15am PT

Got a chance to do the trial run on the 'biner hole drilling.

I used "Tom"'s Original A5 head to find the correct drill location. Tom bought this head and some other stuff when Duece was cleaning out his closet. The drilling had been started but it walked of center. I used a mill to flatten out a spot to restart the hole in the location. I then center drilled it to get a good start for the larger drills.

Mounted and ready to be resurected from the dead:

Positioning:

Milling a flat:

Restarting the hole:

Drilling a 1/4" pilot hole:

Drilled:

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Jul 3, 2010 - 01:18am PT

I did a little custom grinding to the standard high speed steel drill I bought. I want to see how long the cheap drill will last. I releived the back side of the cutting surface and ground the center to a point for faster material removal and easier hole starting.

Set up in the preset fixture:

Not so good shot of the finished grind job:

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Jul 3, 2010 - 01:35am PT

I got started with the real deal. The first D5 head caused a little concern. I dulled the tips of the large drill before I was half way through the head. Not good. I started with a mill bit to flatten the face so I could start a good straight hole. The surface I have to drill into is not perpendicular to the axis the drill is travelling. The entry point and exit point are not parallel to each other either. This makes fro dificult drilling. The drill tips want to catch on the side that makes contact first or they want to deflect away. Either one is not good.

The first sequence I used was: mill, spot drill, 1/4" drill, 1/2" drill, 19/32" drill. I found that the 19/32" drill wasn't taking off enough metal to slow it down and feed correctly. I was going a little to fast on RPMs of the spindle too. I got these straightened out on the second try by slowing the spindle down and skipping the 1/2" drill altogether.

Spot drilling:

Making chips:

More chip making:

Straight off the mill:

Chamfered top:

Chamfered bottom:

Passes the biner test:

This is going to be another slow procces like the milling. The milling and the drilling on the heads are going to be the two cruxes of this project. The tangs and handles are not to big of a deal. I feel that it will be a good finished hammer.

Dutch

Trad climber

pdx

Jul 3, 2010 - 02:05am PT

looks great Moses. Thanks for under taking this endeavor. Keep it up!

Cpt0bvi0u5

Trad climber

Merced CA

Jul 3, 2010 - 03:17am PT

Sick! It's awesome to see this project finally coming together! Keep up the great work and the community appreciates the work that is going into this.

healyje

Trad climber

Portland, Oregon

Jul 3, 2010 - 03:40am PT

Theron, I figured it might take you few permutations to pin down the best approach to drilling the funk hole given what John related, but I have no doubt you'll sort out the most efficient milling / drilling system possible. It all sounds good, and please do keep us posted on the burn rate on the bits and any other changes as many of us find the details fascinating.

Hammers ho!!!

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Jul 3, 2010 - 03:59am PT

Re: Burn Rate

I have gone through two Niagra 3/4" TiCN coated endmills so far with the facing of the hammer heads. This was a result of the mist coolant running out at times. $27 or so each.

Scraped heads: 0

I think that getting the heads in the annealed state has helped in the machining. The softer metal has been easier to cut.

SteveW

Trad climber

The state of confusion

Jul 3, 2010 - 09:56am PT

I hope the red on that hammer head wasn't your blood, Theron!!!!!

Thorgon

Big Wall climber

Sedro Woolley, WA

Jul 3, 2010 - 11:15am PT

Theron,

This is facinating to watch the process!

When can i test one!?

Thanks,
Thor

deuce4

climber

Hobart, Australia

Jul 3, 2010 - 02:24pm PT

Proud.

Looking good, Theron. Nice work. Especially with zero scrap. Took me a head or two to figure out all that out...

cheers

Captain...or Skully

Big Wall climber

Transporter Room 2

Jul 3, 2010 - 03:17pm PT

Very cool stuff, Theron.

Boy, some of these guys ask a lotta questions, huh?
Rock on, Mr. M!

couchmaster

climber

pdx

Jul 4, 2010 - 10:35am PT

Appreciate the update. I just looked up "Labor of Love" and there was a picture of this project in there. Thanks to everyone who worked (and is working) to make this happen.

goatboy smellz

climber

Nederland

Jul 4, 2010 - 10:49am PT

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Aug 20, 2010 - 09:14pm PT

Two funerals and moving to a new to us home has reall put a damper on production. I made good progress in July but August has been swamped with other things.

I got the D5 Logo punch just this week:

The red on the hammer head is Dykem a brush on dye that is thin and used to show where you are machining. It is also used to scribe into for marking where you want to machine.

SteveW

Trad climber

The state of confusion

Aug 20, 2010 - 11:14pm PT

Glad to hear it wasn't your liquids, T!!!!!

Shack

Big Wall climber

Reno NV

Sep 10, 2010 - 12:10am PT

My co-worker who is an old school master machinist suggested 100% carbide drills or EDMing the holes out.

Ihateplastic

Trad climber

It ain't El Cap, Oregon

Sep 10, 2010 - 12:10am PT

I am sure my late dad would frown on me for asking the question, but...

That 'biner hole leaves very little in the way of wall material. Isn't that going to be a weak point after a dozen pitches of slammin' copperheads in tight corners? Were the original A5 hammers that thin in that area?