Hardpan Curmudgeon SASS #8967 Posted September 21, 2019 Share Posted September 21, 2019 Awrighty.... So we have this Cub Scout Pinewood Derby coming up. Budget is pretty much nil, and I got tasked with creating awards. In the past we spent a bundle on trophies. No bundle this year, sooo.... the one thing I'll be buying will be the little brass plates stating what the awards are. I'm going to try to make up a bunch of plaques like the picture below. Local shop donated a big ol' box of used pistons - assorted sizes. Fella at 84 Lumber gave me a good deal on some pine planks. I have plenty of shop tools on hand; plan to first cut the pistons in half with the horizontal bandsaw, clean, then glass bead blast. I'll run the wood through the thickness planer, shape the edges on the router table and add a keyhole slot to the backside.... then stain (oak?) and varnish. But here's my puzzlement. How on earth do I firmly fasten the piston halves and li'l wrenches (cheapies from Harbor Freight, or "Hazard Fraught" as Sassparilla Kid calls it) to the plaques? I gotta make about forty or so of these things, so simple is important.... Any suggestions? Here's the "inspiration sample" picture from the Internet: Link to comment Share on other sites More sharing options...
J. Mark Flint #31954 LIFE Posted September 21, 2019 Share Posted September 21, 2019 screw through the backside to a predrilled hole in the meat of the piston half-same for the wrenches. Alternatively you could drill two small holes and wire things together through the 3rd ring groove. Link to comment Share on other sites More sharing options...
Father Kit Cool Gun Garth Posted September 21, 2019 Share Posted September 21, 2019 13 minutes ago, J. Mark Flint #31954 LIFE said: screw through the backside to a predrilled hole in the meat of the piston half-same for the wrenches. Alternatively you could drill two small holes and wire things together through the 3rd ring groove. Hardpan, Best method. Wire looks ugly and cheap looking. Link to comment Share on other sites More sharing options...
Sedalia Dave Posted September 21, 2019 Share Posted September 21, 2019 2 hours ago, J. Mark Flint #31954 LIFE said: screw through the backside to a predrilled hole in the meat of the piston half-same for the wrenches. Alternatively you could drill two small holes and wire things together through the 3rd ring groove. Other than glue this is your best bet. Link to comment Share on other sites More sharing options...
Duffield, SASS #23454 Posted September 21, 2019 Share Posted September 21, 2019 Drill holes in back side of pistons, use JB Weld to glue screws into the holes. Braze or weld screws to back side of wrenches. Drill holes in plank for the screws. Countersink the holes on the back side of the board for nuts and washers. cut the screws to just shorter than thickness of planks. Bolt pistons and wrenches to planks, sit back and admire your handiwork. That is the complicated procedure, good luck with what ever you decide. Duffield Link to comment Share on other sites More sharing options...
Loophole LaRue, SASS #51438 Posted September 21, 2019 Share Posted September 21, 2019 You've already got a nice big hole where the pin would connect the piston to the connecting rod. Find some washers large enough to catch the edge of the pin opening, and secure with a screw through the washer, the hole and into the plaque. LL Link to comment Share on other sites More sharing options...
Blackwater 53393 Posted September 21, 2019 Share Posted September 21, 2019 There is an adhesive called E6000. It takes a little while to set, but it'll stick ANYTHING together that isn't liquid or covered in a liquid. It is clear and when dry, is odor free. Link to comment Share on other sites More sharing options...
Sedalia Dave Posted September 21, 2019 Share Posted September 21, 2019 4 hours ago, Duffield, SASS #23454 said: Drill holes in back side of pistons, use JB Weld to glue screws into the holes. Braze or weld screws to back side of wrenches. Drill holes in plank for the screws. Countersink the holes on the back side of the board for nuts and washers. cut the screws to just shorter than thickness of planks. Bolt pistons and wrenches to planks, sit back and admire your handiwork. That is the complicated procedure, good luck with what ever you decide. Duffield Sounds more complicated but in the long run I bet it will be easier. Link to comment Share on other sites More sharing options...
J. Mark Flint #31954 LIFE Posted September 21, 2019 Share Posted September 21, 2019 nylon line? Link to comment Share on other sites More sharing options...
Badlands Bob #61228 Posted September 21, 2019 Share Posted September 21, 2019 Gorilla Epoxy. Put it on with one of those little acid brushes. Link to comment Share on other sites More sharing options...
Doc X Posted September 21, 2019 Share Posted September 21, 2019 The pistons will be an aluminum alloy, pretty soft stuff. Drill through from the back into the meat of the piston skirts and use self-tapping metal screws. El-chepo wrenches are sometimes aluminum too. Use the same method just be careful not to drill through. Glue for the plaque. Link to comment Share on other sites More sharing options...
Cactus Jack Calder Posted September 22, 2019 Share Posted September 22, 2019 11 hours ago, Blackwater 53393 said: There is an adhesive called E6000. It takes a little while to set, but it'll stick ANYTHING together that isn't liquid or covered in a liquid. It is clear and when dry, is odor free. Hardpan, just a word of caution. E6000 will eat some plastics. Styrene is one that it will eat. If your plaques are plastic test the glue first. Good Luck! CJ Link to comment Share on other sites More sharing options...
Sarge Posted September 22, 2019 Share Posted September 22, 2019 I like DocX idea about using self tapping screws. Drill some small starter holes into the wrenches then use the self tappers. I've used them for a bunch of auto related repairs and customization. You be surprised how easy they are to use and how well they hold. Link to comment Share on other sites More sharing options...
Smuteye John SASS#24774 Posted September 22, 2019 Share Posted September 22, 2019 Check pawn shops for the wrenches. Every one I've ever been in had handtools. Since it's for the Scouts, you might even get some donated. Link to comment Share on other sites More sharing options...
Dirty Dan Dawkins Posted September 22, 2019 Share Posted September 22, 2019 Chemlink M1 Structural adhesive. Link to comment Share on other sites More sharing options...
Hardpan Curmudgeon SASS #8967 Posted October 13, 2019 Author Share Posted October 13, 2019 Got 'er done~!! Thanks all for the advice! 'Twas a pile o' work, but the outcome was worth it - bunch of happy, smiling kids. Unfortunately, the self-drilling/tapping screws didn't work worth a damn. No prob ~ clamped the piston halves onto the plaques , drilled through then tapped and used 8-32 machine screws. Countersunk the backside for the screws and routed a keyhole slot for hanging. But I came up with a dandy idea for the wrenches! Got a mess of rare earth button magnets, JB Welded two to each plaque, and Bingo! just stuck the wrenches on. Kids loved being able to take 'em off and play with 'em. Oh... used new ones - cheap, a set of 33 for under $20 from Harbor Freight. Ended up only needing 27. Thankfully - this project was a major pain in the patootie. Link to comment Share on other sites More sharing options...
Sedalia Dave Posted October 13, 2019 Share Posted October 13, 2019 6 hours ago, Hardpan Curmudgeon SASS #8967 said: this project was a major pain in the patootie. Maybe but I bet those smiles made it worth it. Good on ya HC. Link to comment Share on other sites More sharing options...
Pat Riot Posted October 13, 2019 Share Posted October 13, 2019 Very cool, Hardpan. I see one kid figured out out how to remove his wrench. He’s got it in his hand and ready to go. Link to comment Share on other sites More sharing options...
Assassin Posted October 13, 2019 Share Posted October 13, 2019 Nice job. Link to comment Share on other sites More sharing options...
Sarge Posted October 13, 2019 Share Posted October 13, 2019 Great job. Glad it worked out for you. Learned a thing or two from your post. Link to comment Share on other sites More sharing options...
Abilene Slim SASS 81783 Posted October 13, 2019 Share Posted October 13, 2019 Cool! Link to comment Share on other sites More sharing options...
Utah Bob #35998 Posted October 13, 2019 Share Posted October 13, 2019 But Pinewood Derby cars aren’t allowed to have pistons. You could just given em a piece of pine. You’re welcome. Link to comment Share on other sites More sharing options...
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