New knob for hitch bike carrier .....

[wquiles]

One of my best friends got an used, but high-end bike carrier designed to go into a standard 2" hitch. It comes with a long adjustment screw that eliminates "play" once in place, making it nice and quiet.

He has the older version, with a plastic knob who's diameter is too large, and rubs when stored on the ground:




The newer version is a smaller diam knob that does not have this problem:




After lots of use, his knob broke. He was sent a new one, but with the same design, so only a mater of time before it breaks again. He asked me I could make him a new knob that would not break again. I did


Before pictures:





I first tried to cut the plastic off with my dremel, but it was glue/pressed in place, so I decided to turn it down on the lathe instead:





Then I found a suitable piece of Al to make the new knob:




After I got the OD, then spot drill, drill to size:



Test fit:

 

[wquiles]

Turn the other side smooth so that I can hold on the indexer, then center:




Nothing scientific - I thought 45deg would work, so went with that:






Go back to the lathe to continue shaping:





Part piece at target length:


Another test fit:



Go back to the milling machine to drill the holes for the two set screws:



Thread holes:



Almost there:

 

[wquiles]

Marked the two spots for the set screws, and drill through the plastic to reach the steel core - don't want this to slip!:



Final test fit:



But that does not quite "look" nice enough for an early Christmas present for my friend .....



Sandblasting to give it an even surface finish:





Pre-heat in oven:

 

[wquiles]

Spray thermally-cured Moly Resin:





Still pretty hot:



Completed knob:



Ready to return to my friend:





Hope this one last him a while

Will

 

[Gary]

Good stuff WQ; wish I had a Mill. Maybe next year.

 

[wquiles]

Thank you

My machinist mentor told me: "the lathe is the one machine that makes me the most money, but many jobs need a milling machine as well". Not only is he right, but it really opens up the work envelope as to what is possible

 

[fiver]

silly question.
wasn't the plastic knob held on with a hex head bolt?

 

[KeithB]

Love the finish coat. Nice work!

 

[wquiles]

silly question.
wasn't the plastic knob held on with a hex head bolt?

I tried that first. Then I was trying to cut pieces with the dremel, to see if I could get it loose somewhat, but it appeared molded in place. It was then when I realized it was much simpler, quicker, and actually safer on the lathe.

Love the finish coat. Nice work!

Thank you for your kind words

 

[creosote]

Nice work.
Looks like it's demise was going in/out a driveway, not storing it on the ground. Just saying.

 

[Ian]

Very nice indeed. Love the super spacer mill vise thingy.

Creosote is right, if sure looks like the old knob died of excessive road rash, evidence also on the bottom of the end plug. They might need a dogleg hitch adapter that steps up and has the tightening mechanism on a much shorter piece of tubing. Ot a 2" piece of flat strap for a skid plate under the knob. Or a chassis lift and bigger tires. Or just watch it going through the ditches and steep parking lot entrances.

 

[Bret4207]

Yupper, Ian and Creosote hit the problem. He needs a riser.

Very nice work and and an equally nice photo essay! Well done!

 

[Brad]

That is some very fine work. The process is what I love seeing.

 

[wquiles]

Thank you guys

I will let my friend know about the raiser as well

 

[Paul Gauthier]

nicely done, wquiles, and your mentor is indeed a wise man, don't know what I would do without my shop.