Kind of a cool project. Made a handle extension for a lightsaber. A friend of mine from college wanted this for his kid. He had the lightsaber from a company just needed the 28" extention which the company does not make.
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The threads at the end are metric M30X.9 but 28tpi seems to work just fine. The hard part was drilling a 1" hole through the center of a 29" piece of 1.375" aluminum. I made a 15" drill extension out of .675" scrap steel and used 3 set screws to hold the bit in place.
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I drilled 14" from each end. I was shocked the 2 holes lined up. Looking down the tube you can't see where the meet. The pain was drilling .100" then pulling the drill out to clear chips and drilling .100" and repeat 280 or so times. I was going to order heavy wall tubing from McMAster and save some of the drilling but ended up ordering 4 solid sticks from Enco with a coupon for the for the price of 1.5 of the tubes from McMaster. Now I need to make a 4 and 5 foot extension.
Jeff
JEFF
Ditto here like BERNIE says.
This is a super project. Well done and Kudos to U !!!
We would also like to know a bit more in exactly how U completed this project.
Just follow us on this ............
When U commenced drilling with the Drill only mounted in the Tailstock U went as deep as the Drill and the Chuck face permitted.
Thereafter U used Your little ingenious "extension" and continued, albeit slowly, painstakingly and patiently, with the Drilling.
Now, did U use a STEADY REST for Your EXTENSION to keep all things longitudinally in line ???
If U say not, may we ask would it not have been better to reinforce this EXTENSION ???
It may have been just a little easier Drilling into Aluminium.
However, as we work lots with Steels including Stainless and other tougher tool Steels as well, we are just thinking ahead as to what kind of problems we may possibly encounter.
In so far as dimensions of Your JIG, we would just need convert to our metric, as this is quite obvious from Your workings.
Would be nice hearing from U
Thanks in advance
LORD BLESS
aRM