I need a favour/help from a UK metal turner

Jul 17, 2005 3 Replies
T

I'm looking to get some "dust caps" made for the sockets on my car. These sockets are on the roof posts and are for the bolts to the roof bars. There are 4 on each side. 2 on the A post and 2 on the B post. The plastic ones have become very brittle and a majority have become damaged or lost. I was hoping to get replacements made from metal (aluminum) but have been told that I'm looking at a very hefty figure of =A3500. I lack the skill and equipment to do this myself and was wondering anyone would mind telling me wether this was a reasonable sum. Each "dust cap" would be about 10-15mm long. The head would have to be at least 10mm across and 2mm thick. It would also require a torx or allen key slot to be cut in the top. So am I being reasonable or could this be about right.



Many Thanks



Oh and here are pictures of the sockets in question



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TrailRat
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Many Thanks

snip- TrailRat

Your links didn't work for me, but from your description, I get the idea you're getting a bid that would be akin to a damned good screwing without a kiss.

Unless some of the details are more involved than you proposed, the most difficult thing to generate would be the socket head. You can get around that problem by using an Allen wrench (hex wrench) ground off square, pushing it with an arbor press to generate the head details you require. Aluminum will make the chore very easy. I'd suggest alloy 6061-T6, or the equivalent found in the UK. You'd start with a hole the size of the width of the key, and slightly deeper, so the chip formed has somewhere to go. It is unlikely to break off, but get rounded and pounded down at the bottom, where it would remain. I can't imagine paying more than about a pound each for them, especially if you can get a kind hearted soul to lend a hand. All you'd need is a small metal lathe and a press of sorts. .

Harold

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Maybe these?

Nick

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Blush!

They seem to work fine, as do the ones listed, at least when you apply them one at a time! Thanks, Nick.

Harold

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