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Re: [BKARTS] Paper Drill -- make your own



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This home-made paper drill works very well. To make it one needs a lathe and
some machinist skills. To use it requires a drill press and virtually no
skill.
    The drill has two parts: the drill proper, and an aluminum cup which
catches the chads.
    Take a piece of 1/2 inch diameter drill rod, 3.625 inches long. Chuck in a
lathe and face both ends, to bring the total length to 3.5 inches.
    1.812 inches from one end, cross drill a .375" hole
    Chuck from the other end. Center drill. Drill a .234 inch diameter hole
until it breaks through into the cross hole. Ream to .250 inch diameter
    Using a sharp tool, turn the outside diameter to .265 inch diameter for a
distance of one inch.
    Center drill the .250" D hole until the edge is sharp.
    Re-ream to .250"
    This completes the drill proper.
    To make the aluminum cup, chuck a piece of 1.500" diameter aluminum so
that 1.75" protrudes from the chuck jaws.
     Center drill and drill .484 inch diameter 1.625" deep.
     Ream to .500 inch diameter.
     Bore a cavity 1 inch deep and 1 3/8 inch diameter.
     Cut off to 1.500 inch length.
     To improve its appearance (but not its utility), reverse the cup in the
chuck and bevel the end of the cup which has the 1/2" hole. The angle of the
bevel does not matter, but 30 degrees looks fine.
     This completes the aluminum cup.
     Using Locktite (any grade), assemble the cup on the drill so that the
cross drill just clears the inside bottom of the cup.
     Chuck the 1/2"D end of the drill in a drill press 1/2" or larger chuck.
Let the top of the cup touch the bottom of the chuck so that chads do not fly
out.
     Place a piece of wood (end grain holds up longer) on the drill press
table. Place a stack of paper on the wood. Clamp down the paper near where you
want the hole to be. Drill at about 200-300 rpm. Chads will flow out of the
cross drilled hole into the cup. When the cup is full, unchuck the drill and
empty the cup.
     Don't worry if the drill turns straw color after some use. If it turns
blue, the speed of the drill is too high.
     This drill could be hardened, but I have found that it works very well in
its annealed state.
     If you want a larger or smaller drill add or subtract the same amount
from the diameter of the 1/4" hole and the 9/32" diameter drill.
     If this description is not clear, send me a self-addressed envelope and I
will send you a mechanical drawing. Contact me if you have questions.
Rupert N. Evans, 101 W Windsor Rd., Urbana, IL 61802-6697 217-337-7833

Rupert N. Evans
501-391 S LaPosada Circle
Green Valley, AZ 85614
520-648-8365
Author of Book-On-Demand Publishing
I love to print and bind books

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