HPBCANADA.COM

Quite often at the ramp I get asked who makes my hardware. I make all my own with simple woodworking tools. Table saw, mitre saw, jig saw, router, drill. I will post pictures of various thing I have made.
Here I a pic of a tiller handle extension I am working on. Started with a 1x2 aluminum flat bar and notched the ends on the table saw. I will add some lightening holes and chamfer or round over the edges with the router.
You may also see in the picture, a trim switch epoxied into a piece of abs pipe mounted on the tiller.
http://rs1250.pbsrc.com/albums/hh533/Ar ... 0&fit=clip

Here are some pics of putting lightening holes into the tiller extension.
I used a 1-1/4",1-1/8",1" and 7/8" forstner bits in a cordless drill. I don't have the luxury of a drill press. A little wd40 for lubricant because that's what was on the bench. It took 35 mins to drill the four holes through 1" aluminum.
I used a 1/4" round over bit in a router. A little parifin wax on the edge of the aluminum stops it from galling. I used to climb cut before I started using wax but the router was difficult to control. Now I mill conventionally. Next step sand and polish.

http://rs1250.pbsrc.com/albums/hh533/Ar ... 0&fit=clip
http://rs1250.pbsrc.com/albums/hh533/Ar ... 0&fit=clip
http://rs1250.pbsrc.com/albums/hh533/Ar ... 0&fit=clip

Nice work! looks like fun. I have made a few pieces for cars and such using some of the same tech. I like the step drill bits that drill the hole and chamfer in the same pass. Its always way cool to make you own, and have it come out working/looking good.