Thread: My (prototype) pinning system

Hi all; I have developed what I think is a reasonably professional way to make pin collars at home with "normal" tools and minimal skill. Prototype pin and collar shown in photo below on an old Genco. It relies on a homemade drilling/positioning jig which is essentially a piece of steel with a few holes drilled in it which allows you to make collars out of 1/8 inch brass rod. If there in any signifcant interest I could put together a series of photos and explanations of the process

If there in any signifcant interest I could put together a series of photos and explanations of the process

Was that a rhetorical question?
Definitely make a picture tutorial.

Definitely would like to see some pics!

I'm curious, are you flattening that collar? It looks like it in the 2nd picture. I would certainly like to see some kind've tutorial!

Yes, please post pics. I'm trying to figure out the process. The "pin" in your pic does not appear to be brass but then there's a raised brass collar underneath leaving the pin elevated from the scales?

Chris L

Well here goes... It may take a few posts to get the pics online...
The jig below is a piece of steel scrap which has 3 holes drilled in it ... a 1/8" hole, a 1/16" hole that proved to be unnecessary, and a combination (stepped) hole that is 1/8" inch part way thru and then slightly smaller than 1/16" the rest of the way thru (actually, I used a #53 drill bit). I made the blind 1/8" hole then continued drilling the #53, which self centred in the bottom of the tapered end of the 1/8" hole.

I hope the pics below work out in the right order to show the steps of the process...
First sand the end of a 1/8 inch rod to get it square (100 grit emery cloth) using the 1/8" hole in the jig to hold the rod. Then use the 1/8" hole to align the rod end with a 1/8" drill bit to create a countersunk end on the rod (a thicker jig might not be a bad idea here). Then the combination hole is used to guide a small (#53) drill bit to drill down the centre of the rod. Actually, once the end is countersunk the smaller bit will self centre without the jig. Ideally, the hole is slightly smalller than the 1/16" rod that you will use for a pin to create a tight fit that you tap together befroe peening the ends of the pin. Then, the combination hole is used to hold the rod end while the collar gets cut off with a hacksaw. Height of the collar is determined by the depth of the 1/8 hole in the jig (next jig I make will be a shallower stepped hole so the collar is not so high). Then, the back of the collar is sanded smooth with emery cloth. The resulting collar has a countersunk top to allow the pin to flare out and hold (similar to a traditional cup washer). Then it gets installed on the razor and the end of the pins get cut just longer than the collars, sanded square, and peened over with very light hammer tapping ( Actually I assembled a pin and one collar and then peened one end of the pin while holding it in a vise before trying to mount it on the razor). In the assembled photo before sanding you can see the end of the pin flared out and binding against the countersunk end of the collar.

Once it was mounted on the razor I sanded it to get the smooth, domed end. To protect the scales during sanding I made a shield out of a sheet of plastic with a hole punched in it for the pin assembly to stick through (you can also make it from a beer or pop can). Final sanding was with steel wool. As an added bonus you should be able to use the combination hole of the jig to help you drill out pins on razors without damaging washers/scales. That's all!

one more pic showing sanding once its on the razor

Cool, how thin can you cut the brass rod?

Originally Posted by ChrisL

Yes, please post pics. I'm trying to figure out the process. The "pin" in your pic does not appear to be brass but then there's a raised brass collar underneath leaving the pin elevated from the scales?

Chris L

You are correct in that the 1/16" rod used for a pin wasn't brass. It is a nickel/siver alloy used for brazing as thats what I was able to find locally (welder supply) and it seems to work well. Its a little harder than brass so a little less likely to bend in the fitting process.

Originally Posted by raghur

Cool, how thin can you cut the brass rod?

I don't know... I will have to try to make a jig with a shallower stepped hole. Here's another side shot to show the height of this collar. I agree its a little too high.

Maybe file down to size vice using Emory cloth.