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Re: [Orchid] Reshaping Hammers  
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From: Trevor
Date: Tue Jul 17 06:29:56 2007
 
     
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>     ... Is it possible to do what I want with just with the tools that
>     I have? 

    In a word, yes. I've done this many times -- almost every new hammer
    it seems, sooner or later -- so yes, it is quite possible. 

    As to whether it's ideal or not is quite another question. As you've
    surmised it can be very slow going. It can also be quite hard on
    your equipment, especially if you're impatient and try to speed
    things up by applying more pressure etc. And it's incredibly messy
    because you have the whole thing in your hands, as opposed to a bench
    grinder where a lot of the dust and grindings are directed downwards,
    or into a dust trap. 

    If you do decide to go this route I would recommend the following: 

    - a full face shield, not just goggles. 
    - a serious dust mask, NOT one of the paper disposable ones. 
    - a full smock that closes around the wrists and neck. 
    - ear protection. 
    - a good selection of grinding wheels, available at auto body or
    marine shops. 
    - water for coolant (you'll need to cool your workpiece frequently). 
    - patience. 

    Note that the grinding wheels mentioned above are usually rated at
    5000 RPM maximum. That's at the very bottom end of the speed chart
    for your garden variety flex shaft so either (a) use a flex shaft
    that can run comfortably at those low speeds or (b) change to
    abrasives that are rated at 10,000 RPM or higher. 

    If you have to use a regular flex shaft (not a low speed version)
    then look for "cut off" wheels which are quite aggressive cutters AND
    can be stacked to form a larger cutting surface. They usually come in
    three grades of coarseness, go for the coarsest you can find. Buy a
    tube or two of them because you've going to be burning through them
    fairly quickly. 

    Go lightly and don't apply too much pressure, take your time, let
    the tool do the work. If you are bogging the machine down then you're
    working it too hard: back off or you'll be repairing your flex shaft
    before you're done. 

Good luck!

Cheers,
Trevor F.
in The City of Light
Visit TouchMetal.com at http://www.touchmetal.com
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