Topic: AKG Active Project part 4

[ts]

OK, my machine shop guy is almost ready to roll. Just need to clarify some numbers. Pretty much all the drawings show an inside diameter at the cap end of 11/16ths. The cap size is 3/4 - 32. The tap size is 3/4 - 32. According to him he needs a bore hole of 23/32, not 11/16, for the 3/4 - 32 tap to get it done properly. Can someone verify this.

[ts]

Thanks Jon.

[willndmb]

i spoke with my guy tonight, he was going over to the machinist house tonight and i told him that 23/32 might be more accurate

[willndmb]

so i saw my buddy tonight
the one guy he asked works in more of a dye/tap/mold place
he told him they can make the colette pretty easy and for cheap but to get everything set up would be a crazy price.
he is passing the info on directly to a machinist who can do the lath and see what he says

[Chuck]

Tool & dye work is pricey.

[ero3030]

he told him they can make the colette pretty easy and for cheap but to get everything set up would be a crazy price.

thats how they keep u coming back for more orders, and u almost have to till u get enough made to balance the set up price verse piece made.   to get the ball rolling, ask them for the set up price and the cost of 4 dozen pieces.  that makes 24 sets.   take both costs and divide 24.  that will be the cost per set.    500 set up + 10 a piece=980/24= $ 40.83 a set.  even if it would be twice that, it still would be dirt cheap.  also, dont forget about powder coating.  ask the machine shop, they may point u in the right direction and get a good deal for the hook up.   ed

[willndmb]

i told them brass was pref, do you powder coat brass?

[Hypnocracy]

I'll offer to Gun Blue if Brass is used..I have the materials and know how...the coating is black and will never peal off....let me check on price for a 4 oz bottle if it is minimal I'd do it for free...

I can also offer to engrave a logo or ID into the brass but my boss would want to charge for that...

[Chuck]

Very cool. That sounds like a great option.
Would the blueing interfere with electrical connectivity if it gets on the threads?

[ts]

I'll try to talk to an outside machinist this week. Setup costs will be big, no doubt. But as ero said, just pass it on. I have yet to turn a piece of aluminum for the prototypes and already have 150 in three new bits. My machine shop said we needed them anyway so I'm not worried about it. One step at a time.

[Hypnocracy]

Chuck that is a concern...I had planned on putting a cork or something on the Capsule end to protect the threads...fine steel wool would get back to a brass surface if there is an issue...

How should the inside of the Colette be treated? Brass will tarnish (go green) if exposed to the elements...the brass I work with has a Lacquer coating to protect it...

[it-goes-to-eleven]

I'll try to talk to an outside machinist this week. Setup costs will be big, no doubt. But as ero said, just pass it on. I have yet to turn a piece of aluminum for the prototypes and already have 150 in three new bits. My machine shop said we needed them anyway so I'm not worried about it. One step at a time.

Weird.  The tooling required to do this is extremely basic.  I would say the most basic, fundamental cutters you'd need to do lathe work.  Plus, you are cutting the threads with a tap, not a cutter.  Very few of the dimensions are critical.

Anyone with some experience can grind the tooling... on a grinder... out of a chunk of tool steel... Total cost, about a quarter.   I have a little shoebox full of those cutters that I acquired with my lathe.  Or you can buy indexed carbide cutters.  Those should only be a few bucks each, plus the holder.  But those are overkill.

[willndmb]

in the end it all evens out most likely but my first guy said they could make them for like $1 each, but the setup charge was "crazy"

[ero3030]

if TS'es boy can make a working prototype, some shop with auto set up should beable pop them out at will.  deff get a set or two that Jon likes and that the peeps on this thread like, and go from there.  send one set to Jon and if is a go, take the other set to a shop or send some where on line.  sort of like a screen print shop.  once u pay for the negitive and they put it on the silk, u can just call up and get another dozen shirts made, the hard part is done.   hope all works out.    here is another thing u can try.  have a local vo-tech near by or know if any of your friends kids go to vo-tech?  stop by, and see what they have to say.  they do out side work for cheap, and if u know a kid going, it could be one of his projects!!  seniors always need a final project to do!!  once the proto is done, thats where i would take iit!!  for sure.   ed

[Chuck]

So, what's a CraZy set-up fee 

$200?

So, make the first batch 50 units X $2.00 each + $200 (set-up) = $300 total
= $6.00 each. Twelve bucks for a pair...
That's reasonable to me.