I've certainly browsed here in the past and I am hoping that someone can o
ffer me some relevant advice, and that this group is not too corrupted by a
ll the political messages I just saw.
I would like to make a spring, actually, about 200 springs. They need to
be extension springs, about 1" long and 0.25" diameter, but tapered so tha
t they can be fit into an Approximately 0.23" diameter hole and will go onl
y half way through. The upper part of the spring will stick out of the hol
e and will serve as an electrical contact for a wire just as in the electro
nics kits of yore.
I need these to be inexpensive (Less than about $0.20 per spring), becaus
e I need a lot of them. If someone knows of a source of custom springs tha
t can make these, please let me know, and the rest of the discussion below
Because they need to be inexpensive, I am thinking the way to go is to bu
y uncut spring stock from McMaster-Carr (e.g. this stuff:
er.com/#9664K47) and cut the pieces into 1" lengths.
But, can I taper them myself? My thought is to make a jig in a drill press
. A 1" length of spring would be dropped into a tapered hole. I would the
n press a pin down the center of the spring to expand the top half into the
tapered hole. I would then push a semi-circular slide into place to retai
n the spring and slide it off the pin as I pull the pin back up. The enlar
ged portion of the spring would be at most 0.5" long, though probably close
r to 0.375" long.
This scheme seems to me like it might work, but I have a few questions.
1) Has anyone done something like this before?
2) I presume the taper has to be a little bigger than the desired ID of th
e spring, as it will spring back a little bit. How much bigger?
3) Does anyone have suggestions on a nice way to cut the spring to length
so I don't have sharp edges that cut fingers?
4) What spring material is most amenable to post-forming?
Thanks, and I look forward to the group's helpful and imaginative response
- posted 6 years ago