I'm looking to a slot the heads of some brass knurled knobs. I was
thinking of mounting them in a line recessed in a piece of wood. I
was going to use threaded inserts to hold the knobs and a jam nut
on the back to fix the knob to hold its depth and keep from rotating.
I can then use my table saw (with an old carbide tip blade) to cut
through the wood, and brass in small increments until I have the slot
at the right depth.

Sound like a bad idea? Suggestion?

On Sat, 08 Oct 2022 18:51:00 -0400, krw@notreal.com wrote:

>
>I'm looking to a slot the heads of some brass knurled knobs. I was
>thinking of mounting them in a line recessed in a piece of wood. I
>was going to use threaded inserts to hold the knobs and a jam nut
>on the back to fix the knob to hold its depth and keep from rotating.
>I can then use my table saw (with an old carbide tip blade) to cut
>through the wood, and brass in small increments until I have the slot
>at the right depth.
>
>Sound like a bad idea? Suggestion?

While this can work for aluminum, a table saw is far too fast for
brass.

Joe Gwinn

On Saturday, October 8, 2022 at 5:51:08 PM UTC-5, k...@notreal.com wrote:
> I'm looking to a slot the heads of some brass knurled knobs. I was
> thinking of mounting them in a line recessed in a piece of wood. I
> was going to use threaded inserts to hold the knobs and a jam nut
> on the back to fix the knob to hold its depth and keep from rotating.
> I can then use my table saw (with an old carbide tip blade) to cut
> through the wood, and brass in small increments until I have the slot
> at the right depth.
>
> Sound like a bad idea? Suggestion?

Use an abrasive cutoff blade.

On Saturday, October 8, 2022 at 5:51:08 PM UTC-5, k...@notreal.com wrote:
> I'm looking to a slot the heads of some brass knurled knobs. I was
> thinking of mounting them in a line recessed in a piece of wood. I
> was going to use threaded inserts to hold the knobs and a jam nut
> on the back to fix the knob to hold its depth and keep from rotating.
> I can then use my table saw (with an old carbide tip blade) to cut
> through the wood, and brass in small increments until I have the slot
> at the right depth.
>
> Sound like a bad idea? Suggestion?

This looks like a pretty good video on cutting metal:

https://www.youtube.com/watch?v=PoubVW08Wy4

On Sun, 9 Oct 2022 07:23:32 -0700 (PDT), Bob Davis
<wrobertdavis@gmail.com> wrote:

>On Saturday, October 8, 2022 at 5:51:08 PM UTC-5, k...@notreal.com wrote:
>> I'm looking to a slot the heads of some brass knurled knobs. I was
>> thinking of mounting them in a line recessed in a piece of wood. I
>> was going to use threaded inserts to hold the knobs and a jam nut
>> on the back to fix the knob to hold its depth and keep from rotating.
>> I can then use my table saw (with an old carbide tip blade) to cut
>> through the wood, and brass in small increments until I have the slot
>> at the right depth.
>>
>> Sound like a bad idea? Suggestion?
>
>Use an abrasive cutoff blade.

That's a good idea. Amazon has 10" metal blades for $11. It says
they're for chop saws but I don't see why it wouldn't work. The max
RPM is in the 6K region so that shouldn't be a problem either. The
manual for the Unisaw says the blade has to be rated for >4000RPM.

Then there is a metal blade "for aluminum and non-ferrous metals":
<https://www.amazon.com/TOMAX-10-Inch-Aluminum-Non-Ferrous-8-Inch/dp/B01LXDARMZ/ref=psdc_552292_t2_B0052IP0GO?th=1>

I intend to bury the screws in a 2x4(?) so the blade won't be exposed
in any case.

On Saturday, October 8, 2022 at 6:51:08 PM UTC-4, k...@notreal.com wrote:
> I'm looking to a slot the heads of some brass knurled knobs. I was
> thinking of mounting them in a line recessed in a piece of wood. I
> was going to use threaded inserts to hold the knobs and a jam nut
> on the back to fix the knob to hold its depth and keep from rotating.
> I can then use my table saw (with an old carbide tip blade) to cut
> through the wood, and brass in small increments until I have the slot
> at the right depth.
>
> Sound like a bad idea? Suggestion?

How many are you talking about here? If it's a handful or less I'd be inclined to do it with handtools..., e.g., hacksaw, slitting file, screw slot file. For relatively small knobs and slots the slitting and slot files would suffice. For relatively large knobs with larger slots the hacksaw would be the place to start. You could take it to the next level and clock the slots so they all line up when tight... e.g., install them with padded pliers and make the slot direction and then cut the slots. ;~)

On Monday, October 10, 2022 at 11:34:39 AM UTC-4, John Grossbohlin wrote:
> On Saturday, October 8, 2022 at 6:51:08 PM UTC-4, k...@notreal.com wrote:
> > I'm looking to a slot the heads of some brass knurled knobs. I was
> > thinking of mounting them in a line recessed in a piece of wood. I
> > was going to use threaded inserts to hold the knobs and a jam nut
> > on the back to fix the knob to hold its depth and keep from rotating.
> > I can then use my table saw (with an old carbide tip blade) to cut
> > through the wood, and brass in small increments until I have the slot
> > at the right depth.
> >
> > Sound like a bad idea? Suggestion?
> How many are you talking about here? If it's a handful or less I'd be inclined to do it with handtools..., e.g., hacksaw, slitting file, screw slot file. For relatively small knobs and slots the slitting and slot files would suffice. For relatively large knobs with larger slots the hacksaw would be the place to start. You could take it to the next level and clock the slots so they all line up when tight... e.g., install them with padded pliers and make the slot direction and then cut the slots. ;~)

That should read "mark the slots" not "make the slots". ;~)

On Mon, 10 Oct 2022 08:34:36 -0700 (PDT), John Grossbohlin
<grossboj@gmail.com> wrote:

>On Saturday, October 8, 2022 at 6:51:08 PM UTC-4, k...@notreal.com wrote:
>> I'm looking to a slot the heads of some brass knurled knobs. I was
>> thinking of mounting them in a line recessed in a piece of wood. I
>> was going to use threaded inserts to hold the knobs and a jam nut
>> on the back to fix the knob to hold its depth and keep from rotating.
>> I can then use my table saw (with an old carbide tip blade) to cut
>> through the wood, and brass in small increments until I have the slot
>> at the right depth.
>>
>> Sound like a bad idea? Suggestion?
>
>How many are you talking about here? If it's a handful or less I'd be inclined to do it with handtools..., e.g., hacksaw, slitting file, screw slot file. For relatively small knobs and slots the slitting and slot files would suffice. For relatively large knobs with larger slots the hacksaw would be the place to start. You could take it to the next level and clock the slots so they all line up when tight... e.g., install them with padded pliers and make the slot direction and then cut the slots. ;~)

The screws are 1/4-20 and the heads 3/4". The width of the slot isn't
all that important. I'd like them to look nice. It's for a Shaper
Workstation. ;-)

I ordered a metal blade from Amazon. The description says it'll cut
brass. I'll bury them in a 2x4 when I'm cutting so I shouldn't be in
too much danger. I looked around online and I found many sites saying
that it can be done but be careful of the "sticky" problem.

On Monday, October 10, 2022 at 10:42:30 PM UTC-4, k...@notreal.com wrote:
> On Mon, 10 Oct 2022 08:34:36 -0700 (PDT), John Grossbohlin
> <gros...@gmail.com> wrote:
>
> >How many are you talking about here? If it's a handful or less I'd be inclined to do it with handtools..., e.g., hacksaw, slitting file, screw slot file. For relatively small knobs and slots the slitting and slot files would suffice. For relatively large knobs with larger slots the hacksaw would be the place to start. You could take it to the next level and clock the slots so they all line up when tight... e.g., install them with padded pliers and make the slot direction and then cut the slots. ;~)
> The screws are 1/4-20 and the heads 3/4". The width of the slot isn't
> all that important. I'd like them to look nice. It's for a Shaper
> Workstation. ;-)
>
> I ordered a metal blade from Amazon. The description says it'll cut
> brass. I'll bury them in a 2x4 when I'm cutting so I shouldn't be in
> too much danger. I looked around online and I found many sites saying
> that it can be done but be careful of the "sticky" problem.

Hand tools ≠ crude. ;~) The gunsmiths at Colonial Williamsburg make screws by hand and those guns sell for $10-20K+ (mostly depending on the barrel and lock used).

On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin
<grossboj@gmail.com> wrote:

>On Monday, October 10, 2022 at 10:42:30 PM UTC-4, k...@notreal.com wrote:
>> On Mon, 10 Oct 2022 08:34:36 -0700 (PDT), John Grossbohlin
>> <gros...@gmail.com> wrote:
>>
>> >How many are you talking about here? If it's a handful or less I'd be inclined to do it with handtools..., e.g., hacksaw, slitting file, screw slot file. For relatively small knobs and slots the slitting and slot files would suffice. For relatively large knobs with larger slots the hacksaw would be the place to start. You could take it to the next level and clock the slots so they all line up when tight... e.g., install them with padded pliers and make the slot direction and then cut the slots. ;~)
>> The screws are 1/4-20 and the heads 3/4". The width of the slot isn't
>> all that important. I'd like them to look nice. It's for a Shaper
>> Workstation. ;-)
>>
>> I ordered a metal blade from Amazon. The description says it'll cut
>> brass. I'll bury them in a 2x4 when I'm cutting so I shouldn't be in
>> too much danger. I looked around online and I found many sites saying
>> that it can be done but be careful of the "sticky" problem.
>
>Hand tools ? crude. ;~) The gunsmiths at Colonial Williamsburg make screws by hand and those guns sell for $10-20K+ (mostly depending on the barrel and lock used).

I'll let you know when I'm done with my gun. I'll expect $20,000.
Cash (PayPal is reported to the 87,000 new IRS agents).

On Tuesday, October 11, 2022 at 9:03:10 PM UTC-4, k...@notreal.com wrote:
> On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin

> >Hand tools ? crude. ;~) The gunsmiths at Colonial Williamsburg make screws by hand and those guns sell for $10-20K+ (mostly depending on the barrel and lock used).
>
> I'll let you know when I'm done with my gun. I'll expect $20,000.
> Cash (PayPal is reported to the 87,000 new IRS agents).

I have connections there... worked for the foundation.

On Tue, 11 Oct 2022 19:22:45 -0700 (PDT), John Grossbohlin
<grossboj@gmail.com> wrote:

>On Tuesday, October 11, 2022 at 9:03:10 PM UTC-4, k...@notreal.com wrote:
>> On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin
>
>> >Hand tools ? crude. ;~) The gunsmiths at Colonial Williamsburg make screws by hand and those guns sell for $10-20K+ (mostly depending on the barrel and lock used).
>>
>> I'll let you know when I'm done with my gun. I'll expect $20,000.
>> Cash (PayPal is reported to the 87,000 new IRS agents).
>
>I have connections there... worked for the foundation.

That's one of the wonders of the world. How did these guys, 250 years
ago, make a rifle? A musket is one thing but a rifle is something
else entirely. Gunsmithing really is high art.

On Wednesday, October 12, 2022 at 12:14:59 AM UTC-4, k...@notreal.com wrote:
> On Tue, 11 Oct 2022 19:22:45 -0700 (PDT), John Grossbohlin
> wrote:
>
> >On Tuesday, October 11, 2022 at 9:03:10 PM UTC-4, k...@notreal.com wrote:
> >> On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin
> >
> >> >Hand tools ? crude. ;~) The gunsmiths at Colonial Williamsburg make screws by hand and those guns sell for $10-20K+ (mostly depending on the barrel and lock used).
> >>
> >> I'll let you know when I'm done with my gun. I'll expect $20,000.
> >> Cash (PayPal is reported to the 87,000 new IRS agents).
> >
> >I have connections there... worked for the foundation.
> That's one of the wonders of the world. How did these guys, 250 years
> ago, make a rifle? A musket is one thing but a rifle is something
> else entirely. Gunsmithing really is high art.

You might be interested in the movie "The Gunsmith of Williamsburg." I saw that movie in school when it first came out (around '69 or '70) and wanted to do it... and about 17 years later I found myself working in the shop as a skilled craft interpreter. It's on YouTube. BTW, there are records of rifled guns going back to the 15th century, i.e., it was nothing new in the 18th century!

https://www.youtube.com/watch?v=bAzJOULyx5c&list=PLLmc7jo1UFm9YLQR_BJVT5JBHs_gu4E9a

krw@notreal.com writes:
>On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin
><grossboj@gmail.com> wrote:
>
>Cash (PayPal is reported to the 87,000 new IRS agents).

Good grief. 50,000 of those are to replace retiring agents,
and the rest just return the IRS to a reasonable staffing level.

On 10/12/2022 9:05 AM, Scott Lurndal wrote:
> krw@notreal.com writes:
>> On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin
>> <grossboj@gmail.com> wrote:
>>
>> Cash (PayPal is reported to the 87,000 new IRS agents).
>
> Good grief. 50,000 of those are to replace retiring agents,
> and the rest just return the IRS to a reasonable staffing level.

They are short staffed, my quarterly payment coupons just made it to my
mail box in time for me to make a payment in April last year. And
refunds seem to be taking much longer.

On Wed, 12 Oct 2022 14:05:29 GMT, scott@slp53.sl.home (Scott Lurndal)
wrote:

>krw@notreal.com writes:
>>On Mon, 10 Oct 2022 20:35:16 -0700 (PDT), John Grossbohlin
>><grossboj@gmail.com> wrote:
>>
>>Cash (PayPal is reported to the 87,000 new IRS agents).
>
>Good grief. 50,000 of those are to replace retiring agents,
>and the rest just return the IRS to a reasonable staffing level.

Tell us about the additional $80B, daddy.

On Saturday, October 8, 2022 at 6:51:08 PM UTC-4, k...@notreal.com wrote:
> I'm looking to a slot the heads of some brass knurled knobs. I was
> thinking of mounting them in a line recessed in a piece of wood. I
> was going to use threaded inserts to hold the knobs and a jam nut
> on the back to fix the knob to hold its depth and keep from rotating.
> I can then use my table saw (with an old carbide tip blade) to cut
> through the wood, and brass in small increments until I have the slot
> at the right depth.
>
> Sound like a bad idea? Suggestion?

I see you've met micky in another group. How that work out for you?

On Sunday, October 9, 2022 at 9:02:16 PM UTC-4, k...@notreal.com wrote:
> On Sun, 9 Oct 2022 07:23:32 -0700 (PDT), Bob Davis
> <wrober...@gmail.com> wrote:
>
> >On Saturday, October 8, 2022 at 5:51:08 PM UTC-5, k...@notreal.com wrote:
> >> I'm looking to a slot the heads of some brass knurled knobs. I was
> >> thinking of mounting them in a line recessed in a piece of wood. I
> >> was going to use threaded inserts to hold the knobs and a jam nut
> >> on the back to fix the knob to hold its depth and keep from rotating.
> >> I can then use my table saw (with an old carbide tip blade) to cut
> >> through the wood, and brass in small increments until I have the slot
> >> at the right depth.
> >>
> >> Sound like a bad idea? Suggestion?
> >
> >Use an abrasive cutoff blade.
>
> That's a good idea. Amazon has 10" metal blades for $11. It says
> they're for chop saws but I don't see why it wouldn't work. The max
> RPM is in the 6K region so that shouldn't be a problem either. The
> manual for the Unisaw says the blade has to be rated for >4000RPM.
>
> Then there is a metal blade "for aluminum and non-ferrous metals":
> <https://www.amazon.com/TOMAX-10-Inch-Aluminum-Non-Ferrous-8-Inch/dp/B01LXDARMZ/ref=psdc_552292_t2_B0052IP0GO?th=1>
>
> I intend to bury the screws in a 2x4(?) so the blade won't be exposed
> in any case.

Don't you have an old Craftsman radial arm saw lying around?

Back in my Soap Box Derby days, we used to use the abrasive cut off wheels
in a Craftsman RAS to cut 1/2"+ steel plates, some has wide as 12". Many,
many slow, shallow cuts.

This is a picture of a rear axle mount. The view is into the rear of my son's car,
the white "walls" being the fiberglass body of the car that tapered to a point at
the rear. The 3/4" square stock running across the picture is the axle. You can
see the holes where it comes through the shell. The other 5 pieces of steel,
including the large base plate, make up the mount. They were all cut on the RAS.

https://i.imgur.com/PYh58Pw.jpg

On Wed, 12 Oct 2022 18:27:04 -0700 (PDT), DerbyDad03
<teamarrows@eznet.net> wrote:

>On Saturday, October 8, 2022 at 6:51:08 PM UTC-4, k...@notreal.com wrote:
>> I'm looking to a slot the heads of some brass knurled knobs. I was
>> thinking of mounting them in a line recessed in a piece of wood. I
>> was going to use threaded inserts to hold the knobs and a jam nut
>> on the back to fix the knob to hold its depth and keep from rotating.
>> I can then use my table saw (with an old carbide tip blade) to cut
>> through the wood, and brass in small increments until I have the slot
>> at the right depth.
>>
>> Sound like a bad idea? Suggestion?
>
>I see you've met micky in another group. How that work out for you?

Actually, I thought I was posting here at first. The signal to noise
ratio is too low for me but as long as I made the mistake I thought
I'd ride it.

I don't know anything about Micky. He tried but a wingnut isn't going
to work. I don't think he read my original post.

On Wed, 12 Oct 2022 18:51:56 -0700 (PDT), DerbyDad03
<teamarrows@eznet.net> wrote:

>On Sunday, October 9, 2022 at 9:02:16 PM UTC-4, k...@notreal.com wrote:
>> On Sun, 9 Oct 2022 07:23:32 -0700 (PDT), Bob Davis
>> <wrober...@gmail.com> wrote:
>>
>> >On Saturday, October 8, 2022 at 5:51:08 PM UTC-5, k...@notreal.com wrote:
>> >> I'm looking to a slot the heads of some brass knurled knobs. I was
>> >> thinking of mounting them in a line recessed in a piece of wood. I
>> >> was going to use threaded inserts to hold the knobs and a jam nut
>> >> on the back to fix the knob to hold its depth and keep from rotating.
>> >> I can then use my table saw (with an old carbide tip blade) to cut
>> >> through the wood, and brass in small increments until I have the slot
>> >> at the right depth.
>> >>
>> >> Sound like a bad idea? Suggestion?
>> >
>> >Use an abrasive cutoff blade.
>>
>> That's a good idea. Amazon has 10" metal blades for $11. It says
>> they're for chop saws but I don't see why it wouldn't work. The max
>> RPM is in the 6K region so that shouldn't be a problem either. The
>> manual for the Unisaw says the blade has to be rated for >4000RPM.
>>
>> Then there is a metal blade "for aluminum and non-ferrous metals":
>> <https://www.amazon.com/TOMAX-10-Inch-Aluminum-Non-Ferrous-8-Inch/dp/B01LXDARMZ/ref=psdc_552292_t2_B0052IP0GO?th=1>
>>
>> I intend to bury the screws in a 2x4(?) so the blade won't be exposed
>> in any case.
>
>Don't you have an old Craftsman radial arm saw lying around?

No, since I hadn't used it in 30 years, I found someone who wanted it.
I gave it away a few months ago to the same friend I gave my Craftsman
jointer to, last year. I was tired of looking at it and I wanted to
put the bandsaw there (to get it closer to the DC).
>
>Back in my Soap Box Derby days, we used to use the abrasive cut off wheels
>in a Craftsman RAS to cut 1/2"+ steel plates, some has wide as 12". Many,
>many slow, shallow cuts.
>
>This is a picture of a rear axle mount. The view is into the rear of my son's car,
>the white "walls" being the fiberglass body of the car that tapered to a point at
>the rear. The 3/4" square stock running across the picture is the axle. You can
>see the holes where it comes through the shell. The other 5 pieces of steel,
>including the large base plate, make up the mount. They were all cut on the RAS.
>
>https://i.imgur.com/PYh58Pw.jpg
>
Impressive. It all looks machined.

Santa Amazon delivered the non-ferrous metal, table saw blade
yesterday so I'll give it a try in the next couple of days.

On Thu, 13 Oct 2022 00:11:33 -0400, krw@notreal.com wrote:

>On Wed, 12 Oct 2022 18:51:56 -0700 (PDT), DerbyDad03
><teamarrows@eznet.net> wrote:
>
>>On Sunday, October 9, 2022 at 9:02:16 PM UTC-4, k...@notreal.com wrote:
>>> On Sun, 9 Oct 2022 07:23:32 -0700 (PDT), Bob Davis
>>> <wrober...@gmail.com> wrote:
>>>
>>> >On Saturday, October 8, 2022 at 5:51:08 PM UTC-5, k...@notreal.com wrote:
>>> >> I'm looking to a slot the heads of some brass knurled knobs. I was
>>> >> thinking of mounting them in a line recessed in a piece of wood. I
>>> >> was going to use threaded inserts to hold the knobs and a jam nut
>>> >> on the back to fix the knob to hold its depth and keep from rotating.
>>> >> I can then use my table saw (with an old carbide tip blade) to cut
>>> >> through the wood, and brass in small increments until I have the slot
>>> >> at the right depth.
>>> >>
>>> >> Sound like a bad idea? Suggestion?
>>> >
>>> >Use an abrasive cutoff blade.
>>>
>>> That's a good idea. Amazon has 10" metal blades for $11. It says
>>> they're for chop saws but I don't see why it wouldn't work. The max
>>> RPM is in the 6K region so that shouldn't be a problem either. The
>>> manual for the Unisaw says the blade has to be rated for >4000RPM.
>>>
>>> Then there is a metal blade "for aluminum and non-ferrous metals":
>>> <https://www.amazon.com/TOMAX-10-Inch-Aluminum-Non-Ferrous-8-Inch/dp/B01LXDARMZ/ref=psdc_552292_t2_B0052IP0GO?th=1>
>>>
>>> I intend to bury the screws in a 2x4(?) so the blade won't be exposed
>>> in any case.
>>
>>Don't you have an old Craftsman radial arm saw lying around?
>
>No, since I hadn't used it in 30 years, I found someone who wanted it.
>I gave it away a few months ago to the same friend I gave my Craftsman
>jointer to, last year. I was tired of looking at it and I wanted to
>put the bandsaw there (to get it closer to the DC).
>>
>>Back in my Soap Box Derby days, we used to use the abrasive cut off wheels
>>in a Craftsman RAS to cut 1/2"+ steel plates, some has wide as 12". Many,
>>many slow, shallow cuts.
>>
>>This is a picture of a rear axle mount. The view is into the rear of my son's car,
>>the white "walls" being the fiberglass body of the car that tapered to a point at
>>the rear. The 3/4" square stock running across the picture is the axle. You can
>>see the holes where it comes through the shell. The other 5 pieces of steel,
>>including the large base plate, make up the mount. They were all cut on the RAS.
>>
>>https://i.imgur.com/PYh58Pw.jpg
>>
>Impressive. It all looks machined.
>
>Santa Amazon delivered the non-ferrous metal, table saw blade
>yesterday so I'll give it a try in the next couple of days.

I built a jig today and tried the first four screws. The jig needs
some work but it worked just fine. The brass knobs cut well. The
problem is going to be getting the depth uniform with each use of the
jig. The inserts I used didn't work at all. I'll try different ones
soon.