OK now time to start making the additions to the key handle that was made on Page 1
The first thing to be made is the tension adjustment holder, many vintage keys had this rather elaborate appendage to the key body on which the big adjuster knob would sit, it certainly makes it look quite Victorian as to whether or not it adds anything to the keys performance is another matter, probably not, but it is part of the key and this is how I make mine
First of all I place a round piece of brass in the clamp and take out a slot the same width and depth as the handle, below you can see the slotting blade actually cutting the slot, care has to be taken to ensure the blade is cutting exactly face on, if the slot is cut at an angle then the slot will be lower one side than the other and won't fit snugly on the the handle.
Then below I cut it off and place it in the lathe to clean it up
You can see I use a rounded lathe cutting tool, this is best for just cleaning rough cut areas and cleaning up surfaces
Having cleaned it up it now needs a small centre hole made, because later after it has been fitted to the key handle it will need to be drilled out to take the adjuster bolt and spring, You can see a small strange drill in the chuck, this is a centre drill and will if correctly used make a starter hole at exactly the centre of the work, next job is to make the same thing only smaller that the knob screws into, this has a slot made in the side as it sits on the end of the key (below)
And finally the contact block, this is a continuation of the handle only slightly thicker and fits just in front of the tension adjuster, its job is to hold the contact spring leaf on which the contacts will be mounted and also adds a bit of weight to the front of the key to balance it nicely, as the others it is cut from a small piece of brass with the slot cutter, just a rough cut at first, it will be trimmed to it's final shape after it has been fitted to the handle.
So we now have all the basic parts to make up the handle, except for the axle which must come later, and below you can see them just pushed together, again imagination is required to visualize the finished key.
And to make it easier for those without much imagination you can see below the handle parts in front of an original key that we are attempting to capture the essence of.
And that is as far as we can go with the handle as next comes the construction of the bearing mountings or trunnion as it is often known, fitting the bearings and aligning the whole thing up.