My BIL needs some special parts made, and I'd like to help him out.
He has lights on his dune buggy that are mounted with a threaded rod through
a round base. The base is flat, but when the light is mounted to the roof,
the roof is slanted, so the lights shine down too close in front of the
I need to find a piece of solid round aluminum or hard plastic or nylon that
I can drill a hole through the center, then slice off portions with one side
at ninety degrees, and the other at the proper angle to make it a tapered
spacer to bring up the light beam. Anyone got a piece of solid nylon stock
1 1/4" diameter, or aluminum the same diameter, or can tell me where I can
purchase such a small amount? Round would be nice, but I could also do it
with a piece of square.
There are three lights, and it would take three inches at max, but would
like a larger piece to be able to hold it in the band saw to cut the angles.
Do you know the angle and center hole diameter? I've got some assorted
stock and could probably make a few wedges and drop them in the mail.
I'd also think you could probably get away with a piece of Sch80 PVC
pipe from Depot/Lowe's from the irrigation sprinkler area.
The hole would be drilled on center. Imagine taking a 1 1/2" long piece of
1 1/4" diameter, drilling a hole longitudinally through the center, then
slicing it at the proper angle to get two exactly matching pieces. One end
flat, the other cut at an angle. That's all I need. Be willing to pay for
them, too. I can e mail pics of the lights, and you'll see how easy this
part I want is.
Answer to various suggestions of cutting board and hockey pucks:
One side of the cylinder would be 90 degrees, the other at a measured angle.
I COULD take a hole saw and cut a hockey puck or cutting board, but then I
would have to take a belt sander or grinding wheel and make the other end
angled. I think cutting a drilled rod would end up with clean parts, and be
a lot easier.
Go buy some tapered alignment shims.(generally steel)
Or go to your local Metal Supermarket of fabricator and ask for some
drop-offs. Usually get them for just over scrap price - and sometimes
even free. Use flat bar stock and slice it across corner, or aluminum
or plastic rounds or square stock. Cut to the angle you need, then
chop off square. Repeat as often as necessary. Square is easier to
handle than round on the saw, as well as on the belt sander (for fine
I've got some in my garage up here in Waterloo Ontario, but would cost
more to send to you than they are worth, even if you are as close as