Domed washers for dummies.

I have been trying the workshop methods of making domed washers and I wasnt very happy with the tube style (just a little on the small side) and without a lathe, turning them from scratch wasn't an option.
Here is what I came up with using what I had....
-1" hexnut (could be substituted for any piece of steel)
-5/32 & 1/16 drill bit
-1" piece of 1/16 rod (I used mild steel, but im sure brass would work)
-Double wide brass washers (from microfasteners)
-1/4" rod 1" long (annealed drill bit)
-Suitable anvil and hammer

Step by step:
-Drill 1/16 pilot hole through one side of the nut
-Enlarge hole with the 5/32, just as deep as the head of the bit
-Taper both sides of your 1" 1/16 rod
-Drill a 1/16 hole in the center of the 1/4" rod appox. 1/4 deep
-Insert your 1/4" rod (drilled side down) into the drill press (run it on slow) and using a flat needle file, shape it to have a 5/32" taper, shoulder the rest flat.

Making the "dome"
-Insert your 1/16 rod into your drilled hole in the nut, leaving 1/4" protruding
-Slide double wide washer onto protruding rod
-Slide 1/4" rod onto he 1/16 rod until snug
-30 light taps with a 4oz hammer
-Remove 1/4" rod and remove washer

Interesting...I may have to play with this technique. Looks simple enough to have fun with tonight.

Just today I handed my buddy a few to replicate. He owns a machine shop so he is going to make a simple press die that I can use in a hydrolic press. I asked for a die that can make a dozen at a time. My fingers are crossed...That is doesnt cost too much.

I had been experimenting with making 2-3-4 at a time, but they lose the outer ring shape and just become a dome. I hope it works for you though!
Eric

I have been doing a single dome with out the shoulder for a few years. I really like your final product. I am going out to the shop and giving this a try. Thanks for sharing

I made a die and punch that slide in a sleeve and didn't do any better than you for a lot more work! Well done!

~Richard

I very much like the simplicity of your method, thanks for posting it with good explanation and pictures.