View Full Version : Custom Pump Handle project: Progress, updates, lots of pics

12-04-2007, 04:24 AM
So im making an aluminum pump handle for my CCM kit to go on my Twister. Here's a thread with pics showing my progress, details on the machining, and so on. Hope you enjoy.

Basic plan, for simplicity's sake, is to turn and part the original acrylic CCM handle, so I dont have to drill and tap the rear holes (which would be a minor headache to accurately locate, and im lazy) for the guide rods and screws for the pump plate. Then to bore out a piece of 1.5" (6061-T6) aluminum to press fit onto the remaining handle section, then knurl/taper/turn the handle to my specs. Maybe anodize it in the future.

Just started work on it today, going to leave it a bit longer than standard (4.5" as opposed to 4.0"), finished turning/parting the acrylic handle, quickly turned the aluminum stock just to start with a decent finish, faced and center drilled both ends, drilled out the depth with a 3/4" drill bit, and working on boring out the ID for the press fit.

Notes: Turned the acrylic at 1260 RPM, could go much faster. Only needed a drop of cutting oil on the machined surface to obtain a clear finish. Turned the aluminum at 1260 RPM, brought it down to 630 RPM when drilling after experiencing to much chatter. Adjusted boring bar for rigidity due to noise when boring, need a longer, bigger, sturdier setup for finishing the bore.

Pics: [Please forgive, cell-phone quality-]

12-04-2007, 04:24 AM

12-04-2007, 04:09 PM
shouldnt you anodize it before you put it on the acrylic handle? i would think the acid would eat the acrylic away if it was together

12-04-2007, 10:56 PM
Realized I wanted to keep it raw, so I polished it up nice.

Finished it today, ill get a pic up of it a bit later, liking how it turned out, made a few mistakes, but very pleased with it.

Der Cockermeister
12-18-2007, 08:56 AM
i think it would look sweet if you used a rounded bit, made a shallow cut and kicked on the autofeed on the lathe. it would take some experimentation with the feed rate, but you could probobly create a pattern similar to the twisters milling.

12-21-2007, 02:48 AM
I actually tried just that 2 weeks ago, didnt work out so well, too much rub. However, with a ball end mill, it just may work, hence why I'm going to be CNC'ing a barrel for my twister in a few months ;)

Ill get a pic up of the handle soon, I swear! I just got my comp back up and running. Just switched to Linux to boot.

12-21-2007, 08:52 PM
your just talking crazy talk man!!!!!!

wow nice pump handle!!!!

12-21-2007, 11:06 PM
Alright stop begging:
(Cell phone pics and bad lighting, shhhh)

Heres a gas-through I made, ran out of time to knurl, since doing the 1/2" NPT threads single point took me longer than expected.

12-21-2007, 11:15 PM
did you make the back plate, or use ccm's??

12-21-2007, 11:20 PM
How much would it cost to have you do something like that for someone else? The reason I'm asking is I'm working on a custom pump and would love to have an anodizable pump handle...and all of them these days seem to be made out of plastic or CF.

12-21-2007, 11:47 PM
I used CCM's back plate.

Cost? Not really interested in making any more, and I doubt ill have the time to for a couple months.

I still have enough aluminum round stock to crank out two more, hmmm tempting.

12-23-2007, 04:51 PM
Looks nice I especially like the gas thru.

Der Cockermeister
12-24-2007, 06:30 AM
looks awesome!

I actually tried just that 2 weeks ago, didnt work out so well, too much rub. However, with a ball end mill, it just may work, hence why I'm going to be CNC'ing a barrel for my twister in a few months

should be no problem at all, it'd just be basic helical interpolation. shouldn't take more than 10 minutes to draw up and convert to g-code.