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Brass workholding for making a tool holder

John Whitley

John Whitley

Joined
Jul 18, 2020
Messages
188
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191
Location
Seattle, WA
Since learning that brass can be turned on a wood lathe (e.g. turning brass nuts for ferrules), I've been contemplating drilling and turning some brass rod to make an interchangeable tool holder for a custom handle, similar to how D-Way's and other such handles work. But I've hit a snag: I'm finding it difficult to get solid workholding on brass round bar (1.25" in the current instance). As in, obviously insecure, not safe to turn the lathe on. I have a fair range of jaws and nothing's even really close. I was hoping that Vicmarc's 35mm pin jaws would work but they deflect quite a lot, leaving a very poor grip.

So my question: does anyone have any good ideas for how to chuck up round metal bar for a project like this? I'd be happy to use a metal lathe chuck, but I have limited experience with metal lathes and I'm having difficulty finding out how/whether I can use or adapt those chucks for my lathe (1-1/4 x 8 TPI headstock w/ the usual 2MT bore). Any pointers would be greatly appreciated!

For clarity, here's my current (rather tentative) workflow:
  1. Rough cut the brass rod to my target length plus chucking length using a hacksaw (or perhaps I'll make a bar cutting jig for use with a jigsaw and metal cutting blade)
  2. Drill out the central bore with a bit modified to zero rake for brass cutting. Could use drill press or lathe.
  3. Drill the tap-dimensioned holes for two set screws (A letter 'F' bit for 5/16-18 threads)
  4. Tap the set screw holes
  5. Put it on the lathe between chuck and cone center on the tailstock
  6. Turn a tenon for mounting in the handle and shape the visible part of the holder
  7. Sand, polish, etc. on the lathe
  8. Part off, or dismount and cut
  9. Make handle and mount the holder
 
1. something I did years ago, to turn an octagon piece of steel when all I had was a three jaw chuck. I tapped the hole in the center of the end and put in a short 5/8 bolt with the head cut off. I then mounted the round part of the bolt in the three jaw metal lathe chuck. It was still about 6 thousandths off center but not enough to make a difference for what I was making. also because it wasn't the sturdiest hold, I took very light cuts with the metal lathe cutter..

2. Make a wooden collet to slip over the brass rod. Turn round stock about 2.5 inches diameter (your large chuck jaws diameter for best hold.) out of the densest wood you have. Drill a hole in the wood's center to a snug fit over about 2 inches of the rod and cut a slit with a fine kerf saw so that you have two or four wooden jaws to contract around the brass rod. Clamp it tight with some hose clamps. mount the round into your larger chuck jaws. mount the other end of the rod in your live center. turn your contour taking very light cuts, flip the thing around to finish the end in the wooden collet.

BTW, is it soft or hard brass? Does it need to be annealed? (I have had soft brass that I could shave with a pocket knife and hard brass that was even tough to file.)
 
Perry Hilbert said:
[…] Make a wooden collet to slip over the brass rod.
Click to expand...
Ah! Making a wooden collet is a neat idea. I’ll definitely keep that one in my back pocket. Thanks.

Perry Hilbert said:
BTW, is it soft or hard brass? Does it need to be annealed? (I have had soft brass that I could shave with a pocket knife and hard brass that was even tough to file.)
Click to expand...

It’s alloy 385, of which the vendor says: “machines comparably well to 360 free-machining brass”. Should turn up just fine, I think.
 
If the brass rod slips in the jaws, then drill and tap for a brass screw that will stick out and sit between the jaws, that would stop it from slipping.

I have held brass in my Oneway Stronghold and had no problem, though I do have a metal lathe if needed.
 
Leo Van Der Loo said:
If the brass rod slips in the jaws, then drill and tap for a brass screw that will stick out and sit between the jaws, that would stop it from slipping.
Click to expand...

Another fine idea, thanks! I’ve got a passel of jaws and none of them are close to a secure fit, so rotational slipping isn’t even a problem I can have yet. I’ll be giving that Grizzly three-jaw chuck a try. For round metal stock it looks promising.
 
Vincent Vogel said:
Don't know if it would help you but August issue of American Woodturner has an article on a shop made collet chuck from pvc and wood. Looks pretty easy to make.
Click to expand...

Thanks for the reminder. I’d seen that around when it came out, but it hadn’t really “clicked”. That’s a pretty interesting approach to custom collets.
 
And likewise, there's Robust Tool's handle collet system. Matt Monaco was using that at the recent PTSW workshop. It's super fast to change to a tool of the same shank diameter, but a little slower if you also need to do a collet change. I actually have one of those I'll be using for a new custom handle soonish, but still want to to a DIY job in brass. I view the brass project as a good starter, as I think there are interesting possibilities beyond just tool handles for brass/aluminum and wood combinations in turning.

Perry Hilbert said:
i like Leo's idea best. it is a similar to a lathe dog and would not require another chuck.
Click to expand...
Good point, but I don't have a Oneway chuck and I do already have Nova and Vicmarc chucks... so it would indeed require another chuck! (I am apparently not far along enough with Turner's Disease that I think owning three different brands of chucks and their associated jaws are a good thing. )
 
Doug Freeman said:
@John Whitley I took the easy way out and use these holders. Anodized AL instead of brass but they work well

Cindy Drozda - Tool Handle Adapters

Elegant, Exquisite, Museum Quality Lidded Finial Vessels and Urns hand made by Woodturner and Artist, Cindy Drozda. Woodturning instruction, Demonstrations and Instructional DVDs.
www.cindydrozda.com
Click to expand...
Mike Hosaluk makes an adapter that looks very much the same, but it’s steel - Packard sells them.
 
I have an old three jaw chuck that I use on the pedestal drill for end drilling rods it simply sits flat on the table, with the extra length of rod hanging through the centre hole on the drill table. Finding the centre of the rod is not difficult with a centre finder and when this is for a handle etc having accurately concentric really isnt necessary. I have done quite often, although I do have a metal lathe its age and accuracy dont help and I find the drill method simple and effective.
 
hughie said:
I have an old three jaw chuck that I use on the pedestal drill for end drilling rods [...]
Click to expand...
That's also an interesting idea. In my case, I already have both a drill press vise which can center rod stock vertically, and a custom jig which attaches to the drill press table for end-drilling long stock (round or rectangular) off one edge of the table. But that does open up the idea of simply through-drilling the entire brass workpiece and mounting it between cone centers.
 
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