Re: Making the TFF Aerial
Posted: Sat Oct 27, 2012 9:50 pm
At last..The Line Guard finished!!
..Sorry that this hasn't been posted before but I haven't been able to do any work on this for a while..
Anyway; have finally finished the optional line guard, as per the initial criteria. It was a bit of a long-winded way of doing it but the strongest-and safest way of attaching it was by screwing to the backplate with 4 countersunk machine screws. It would have looked neater attached to the rim but that was asking for trouble.
While the reel was on the bench, I added a couple of modifications, which are definite improvements. The first was that, the line drum was never quite flush with the inside of the backplate. This has now been rectified by removing the spindle and counter boring the inside of the backplate by 0.020" (1/2 millimetre) which has greatly improved the appearance. The second thing was that, I was never too happy about the top of the spine, not being attached to the back, so whilst it was back on the lathe, I drilled & tapped two discreet holes for brass machine screws to go through from the inside. ..Am happy about that now!
I'm sorry that I didn't take any pictures during the build but was not too good; but here's a brief description of how it was put together..
I based the design on some pictures of an Aerial in the 'Traditional Reels' section. I was going to make it from ali. but thought it might be a bit too fragile so decided on phosphor bronze, cut from an old, worn-out engine bearing, bought very cheaply from a scrap merchant! (an excellent source of small pieces of metal, providing you don't mind getting your hands dirty removing it from it's existing location!)
This was put up in the lathe and a small part of it turned to an inside diameter of 3.975". The actual reel diameter is 3.935" (almost 3 15/16") so this gives a running clearance of 0.020". I turned the outside diameter to give a width of 3/16" but in retrospect, I could have got away with 5/32"..never mind.
Before 'parting off' to a thickness of 1/16", I drilled two 'sets' of locating holes, using my drilling attachment, to give perfect the spacing needed, if the guard is to be interchangeable.
The next thing was to make the little brackets, which were from brass strip, hand filed & drilled. Next, I partly-dismantled the reel and put it up in the lathe, to drill and tap the mounting holes. Accuracy was vital, otherwise the screw holes would not line up..
Next, the bronze 'ring' was cut in half, then trimmed, end details being hand filed in. The spacers were turned, drilled through and tapped for the screws. The rollers were made from 3mm diameter, 316 stainless, with turned-down ends, then the whole assembly was put together, positioned on the reel and the screws tightened.
The assembly was then removed as a unit and the little brackets soldered on. The whole thing was then cleaned up & given a polish.
I have positioned it for RH wind but it can be easily changed by removing the little brass blanking-off screws and re-positioning to the alternative setting place.
So..Here is the TFF in it's final form.. The lineguard adds to the weight and may prove to be more trouble than it's worth; but that was the criteria, which has now been met. However, it is easily removeable and does give some protection to the bottom of the reel..
Best wishes & regards to all,
wm+
..Sorry that this hasn't been posted before but I haven't been able to do any work on this for a while..
Anyway; have finally finished the optional line guard, as per the initial criteria. It was a bit of a long-winded way of doing it but the strongest-and safest way of attaching it was by screwing to the backplate with 4 countersunk machine screws. It would have looked neater attached to the rim but that was asking for trouble.
While the reel was on the bench, I added a couple of modifications, which are definite improvements. The first was that, the line drum was never quite flush with the inside of the backplate. This has now been rectified by removing the spindle and counter boring the inside of the backplate by 0.020" (1/2 millimetre) which has greatly improved the appearance. The second thing was that, I was never too happy about the top of the spine, not being attached to the back, so whilst it was back on the lathe, I drilled & tapped two discreet holes for brass machine screws to go through from the inside. ..Am happy about that now!
I'm sorry that I didn't take any pictures during the build but was not too good; but here's a brief description of how it was put together..
I based the design on some pictures of an Aerial in the 'Traditional Reels' section. I was going to make it from ali. but thought it might be a bit too fragile so decided on phosphor bronze, cut from an old, worn-out engine bearing, bought very cheaply from a scrap merchant! (an excellent source of small pieces of metal, providing you don't mind getting your hands dirty removing it from it's existing location!)
This was put up in the lathe and a small part of it turned to an inside diameter of 3.975". The actual reel diameter is 3.935" (almost 3 15/16") so this gives a running clearance of 0.020". I turned the outside diameter to give a width of 3/16" but in retrospect, I could have got away with 5/32"..never mind.
Before 'parting off' to a thickness of 1/16", I drilled two 'sets' of locating holes, using my drilling attachment, to give perfect the spacing needed, if the guard is to be interchangeable.
The next thing was to make the little brackets, which were from brass strip, hand filed & drilled. Next, I partly-dismantled the reel and put it up in the lathe, to drill and tap the mounting holes. Accuracy was vital, otherwise the screw holes would not line up..
Next, the bronze 'ring' was cut in half, then trimmed, end details being hand filed in. The spacers were turned, drilled through and tapped for the screws. The rollers were made from 3mm diameter, 316 stainless, with turned-down ends, then the whole assembly was put together, positioned on the reel and the screws tightened.
The assembly was then removed as a unit and the little brackets soldered on. The whole thing was then cleaned up & given a polish.
I have positioned it for RH wind but it can be easily changed by removing the little brass blanking-off screws and re-positioning to the alternative setting place.
So..Here is the TFF in it's final form.. The lineguard adds to the weight and may prove to be more trouble than it's worth; but that was the criteria, which has now been met. However, it is easily removeable and does give some protection to the bottom of the reel..
Best wishes & regards to all,
wm+