dfurlano
Member
Ok, this is what I did. (click to enlarge)
Cut the casing on a band saw. Yes it is dangerous so be careful.
Then I cut the end off. Yes you can get hurt on a band saw so be careful.
guage the length you need for the clip and mark a tab.
Cut the tab. Yes the bandsaw can catch and kick the brass so be careful.
Get a grip - and hold the casing on the side.
Start whacking the casing. Go slow and flip from side to side to keep it even.
Work the end closed. See photo.
Close the end up as round as possible.
Start closing the sides up.
Close the sides as round as possible.
Nice and closed.
Start to flatten end.
Continue to flatten from the back side. I try not to hit it to much on the front.
Make sure you work the sides. As you flatten it will spread out. Bring it back together by whacking the sides.
Work the tip sides also.
Flatten more. Keep the inner edges together.
About now I switch to holding the clip with pliers. You need to really start to whack the casing.
Work the sides some more.
Haul off and really smack the bugger.
Work the front carefully. No big dings.
Nice!
Work the sides especially the tip or it will come out crooked.
Shape the sides also.
Flatten more. Is this the worlds longest post?
Very close now!
Bend the end. I stood this on the tab end and tapped the top.
Done. I then filled the clip with solder and shaped it with various files, dremel wheels and finally buffed it. Need to be careful if you solder the back. If you try and solder the clip on the casing you can flow the solder on the back of the clip and stick it to the casing. Also someone told me you can get gold colored solder. I just used the regular thin stuff you use on circuit boards.
If you made it this far here is a photo of some ongoing projects.
Hope this helped.
Cut the casing on a band saw. Yes it is dangerous so be careful.
Then I cut the end off. Yes you can get hurt on a band saw so be careful.
guage the length you need for the clip and mark a tab.
Cut the tab. Yes the bandsaw can catch and kick the brass so be careful.
Get a grip - and hold the casing on the side.
Start whacking the casing. Go slow and flip from side to side to keep it even.
Work the end closed. See photo.
Close the end up as round as possible.
Start closing the sides up.
Close the sides as round as possible.
Nice and closed.
Start to flatten end.
Continue to flatten from the back side. I try not to hit it to much on the front.
Make sure you work the sides. As you flatten it will spread out. Bring it back together by whacking the sides.
Work the tip sides also.
Flatten more. Keep the inner edges together.
About now I switch to holding the clip with pliers. You need to really start to whack the casing.
Work the sides some more.
Haul off and really smack the bugger.
Work the front carefully. No big dings.
Nice!
Work the sides especially the tip or it will come out crooked.
Shape the sides also.
Flatten more. Is this the worlds longest post?
Very close now!
Bend the end. I stood this on the tab end and tapped the top.
Done. I then filled the clip with solder and shaped it with various files, dremel wheels and finally buffed it. Need to be careful if you solder the back. If you try and solder the clip on the casing you can flow the solder on the back of the clip and stick it to the casing. Also someone told me you can get gold colored solder. I just used the regular thin stuff you use on circuit boards.
If you made it this far here is a photo of some ongoing projects.
Hope this helped.
