Make your own solid brass washers

I've been making my own solid brass domed washers for a while now. I got the idea from an older thread but have made a few adjustments that work well for me. That thread is http://straightrazorpalace.com/works...-vlad-how.html so while it's been discussed before, there has been some interest in this lately so I thought I'd renew the topic and share some of what I do for making these. I posted some of this in a different thread a few months ago but have made a few improvements since then.

I cut some steel rod and drilled 1/16 inch holes in the center of a few pieces. On a couple I dished out the surface using larger drill bits and made two sizes for the domes. I cut pieces of seamless brass tubing (two sizes) and use a broke off piece of 1/16 drill bit as the post. Then I hammer the two pieces together and it squishes the tubing into the dome shape.
Attachment 256496Attachment 256497Attachment 256498Attachment 256499Attachment 256500

Then I flatten the bottom on 400 grit sandpaper and the bevel out the top a little to allow for the pin to set flush. I hold it with a small needle nose pliers and use a little bigger drill bit to do this. Doing this part on sandpaper helps the washer to not spin. Attachment 256503Attachment 256504

Now they are ready for sanding and polishing. I set out a progression of sandpaper bits 400 - 2000, some 3.5 diamond lapping paste, a small rag, a slim cone shaped diamond rotary bit for a mandrel, and safety glasses. I used to use a modified roofing nail as the mandrel but the diamond rotary bit is key, it holds the washer and doesn't let it spin, very useful for this next part. I put the washer on the mandrel in the dremel, get it spinning and use the sandpaper to smooth out the surface ending with the diamond polish.
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Here's how they look on some razors I restored...
small domes:
Attachment 256509
large domes:
Attachment 256510

Thanks for looking!

Very cool.

Try a Flex shaft, $15, it will change your life…

No really, gives you a lot more control. Make sure to get the right size for your collet, apparently, there are 2 sizes.

Fantastic work tuzi looks great!

Amazing! Love the look of them.

Slick job sir!
Look terrific.

Those are outstanding Tuzi! Very well done.

Fantastic, thanks for sharing!

How well do the solid collars conform to the curved surface of some scales? Particularly at the pivot end. I've tried some solid collars in the past and had a devil of a time with that. Hollow collars made from stamped sheets conform fine. Nice approach to making the dies.

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Originally Posted by karlej

How well do the solid collars conform to the curved surface of some scales? Particularly at the pivot end. I've tried some solid collars in the past and had a devil of a time with that. Hollow collars made from stamped sheets conform fine. Nice approach to making the dies.

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The small size ones work ok for that but the larger ones don't conform very well, I think you would have to hit them too hard. I have run them back and forth on a half round diamond needle file a few times and had good results with that to put the curve there to match scales. You're right, the pivot end is usually a more pronounced curve.

Good information!
Using similar tooling, I went with the idea of a flexible washer. I tried the solid ones I made but they always stood proud of a contoured scale unless sunk into the scale. I had use of a metal lathe so I made these parts. They slide together in a tube to assure alignment. I use punched out disks of brass or German Silver as a start.
Attachment 256594
I use a HF little punch set that makes small disks. I used a Bremel cutting wheel to grind the end of a hardened ¼" Dowel pin to a centered 1/16th" pin and assured a square shoulder on the dowel, for the punching part... I drill a bunch of 1/16th holes in the shim stock and then use the pin on the dowel to align the punch. A whack with a hammer and I have a disk.
Just a few other ways to accomplish and end.
Have fun!
~Richard

Nice work xaiotuzi and Geezer.

Geezer, do you have any problem with the washer flattening while peening?

Good question! I use a .156/ 5/32s washer with a .078 / 5/64ths hole as a backup; as back in days of yore. Big one snuggles in and little one takes the strain.

The problem I have with lots of solid collars is a 1/16 hole in them is too tight to peen properly using 1/16 rod.
IMO, the rod will seize to the collar quickly and shall not be 'pushed-down' to make a tight job.
As the rod mates-up and seizes to it, anything else is bending the pin.

Therefore, I can also recommend at least a 5/64 hole in collars to use with 1/16 pins.

You're right, the 1/16 hole gets tight and I usually will ream them out some with a diamond bit if needed. It would probably be better to use 5/64 and I may look into that. Wouldn't take much to just make the holes in the steel rod a little bigger. I keep trying to make improvements to the kit. Would need different tubing with larger inside diameter.

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Originally Posted by xiaotuzi

You're right, the 1/16 hole gets tight and I usually will ream them out some with a diamond bit if needed. It would probably be better to use 5/64 and I may look into that. Wouldn't take much to just make the holes in the steel rod a little bigger. I keep trying to make improvements to the kit.

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TBH, a 5/64 hole in the scales is also beneficial. Pushing as peening will allow for more precise alignment.

"A little here...Means a LOT there!' ;)

“Wouldn't take much to just make the holes in the steel rod a little bigger. I keep trying to make improvements to the kit. Would need different tubing with larger inside diameter.”

Just, super glue them to a popsicle stick and drill them, then pop them off the stick.

That is really impressive looking pins you created! Thanks for sharing how you do it with us:)

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Originally Posted by Euclid440

Just, super glue them to a popsicle stick and drill them, then pop them off the stick.

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That's a terrific idea, it's hard to hold these things. A simple solution and I will use this method a lot I'm sure, thanks for this!

Likely, you might hold them with pliers and oversize them a bit with a round jeweler's file or bit/hand-vise before the polishing process?

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Originally Posted by sharptonn

Likely, you might hold them with pliers and oversize them a bit with a round jeweler's file or bit/hand-vise before the polishing process?

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That's what I've been doing to get the recess in the top for the pin to set in. It works ok but the washer really wants to spin in the pliers. I do it on sandpaper to give the bottom something to grip and still tends want to spin. I'm trying not to grip them too tightly so not to mark them up too much before sanding/polishing. I think a little super glue is a great idea, and after popping them off the stick it would be easy to get any left over glue off the washer.

That is outstanding! Thank you much for sharing the process! (And beautiful work, by the way.)