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Door knob collar

How to replicate this item

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Plasma15/05/2019 19:21:40
331 forum posts
41 photos

20190515_174849.jpgHi all,

Small project for the woodhouse.

Many of the original door locks and furniture have been lost over time.

I need to replicate a number of these disc like face plates which have a dished face.

I can part off each disc from brass bar but I'm wondering about the best was to make the curved detail.

Any ideas would be much appreciated, looks like the original was cast.

20190515_174838.jpg

Brian Oldford15/05/2019 19:26:56
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549 forum posts
4 photos

How many do you need to make?

JasonB15/05/2019 19:30:54
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Moderator
16051 forum posts
1687 photos
1 articles

Just grind up a form tool, back can be left flat.

RobCox15/05/2019 19:34:14
25 forum posts
11 photos

A form tool might be too much of an ask for that large a curve, so I'd opt for shaping it freehand with a graver. Depends how confident you are with freehand turning. I've 20+ years of woodturning experience and have used that to shape machine handles from steel, so a bit of brass shouldn't be too difficult.

Rob

JohnF15/05/2019 19:41:28
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853 forum posts
102 photos

Plasma, depends on the size of lathe you have but assuming a smaller machine I would cut off suitable size piece from the bar stock, use soft jaws bored to accept the billets then use a form tool to make the large rad -- probably face up and centre drill to use the tail stock for added support. Then drill and bore the hole and recess - ensure recess is a consistent size.

Next make an expanding mandrel to mount in the chuck so that you can mount the part on the larger recess then face up and produce a small - say .010" - .-020" recess to make sure it sits flat on the wood. The rest is easy - holes etc

Hope this helps John

Faster typer's than me !

Edited By JohnF on 15/05/2019 19:42:55

not done it yet15/05/2019 19:43:55
3248 forum posts
11 photos

You could make them in aluminium and coat them with one of those ‘patina’ solutions. A cheaper option, or maybe not...

Plasma15/05/2019 20:32:09
331 forum posts
41 photos

Gents,

I have a pair of Boxford X10s and a model L S&B with internal step chuck so holding it should not be too much of a problem.

I had though of a form tool, or series of tools for the S&B capstan reform different aspects of the shape.

At first I need 4 in number but bearing in mind the house has in excess of 365 rooms, each with at least two doors (state rooms even have false doors that do nothing but achieve symmetry) I think I may be making a few more.

The three holes are later additions as the two holes inside the knob shank would have held the face plate invisibly, but not after a few hundred years of wear.

Sorry if I'm using poor lock terminology but I'm no locksmith.

Best regards Mick

Michael Gilligan15/05/2019 20:49:43
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13827 forum posts
603 photos

With those quantities ... Casting might actually be a realistic proposition

H&S legislation limits what can be done in the UK, but India does a lot of Brass.

MichaelG.

.

Edit: a few moments on google returned this list:

https://m.indiamart.com/impcat/brass-castings.html

Edited By Michael Gilligan on 15/05/2019 20:54:43

John Haine15/05/2019 21:10:08
2591 forum posts
133 photos

CNC. Or make a press tool?

pgk pgk15/05/2019 21:18:32
1426 forum posts
278 photos

They look awfully familiar somehow...
Of no idea if it helps but there used to be a shop between barnes and putney (london) called knobs and knockers (don't think it was a brothel) but lookig for it on line I found this link: **LINK**

Or a salvage yard 'cos they look like a stock common item...?

pgk

Neil Wyatt15/05/2019 21:21:08
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16446 forum posts
686 photos
74 articles

Plenty of look-alike brass doorknobs out there...

Jeff Dayman16/05/2019 00:28:08
1597 forum posts
39 photos

+1 for press tool, preferably run in the brothel pgk pgk mentioned. (more strokes per minute in the press, when run there)

Hopper16/05/2019 01:09:56
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3657 forum posts
72 photos

It's easy enough to turn those types of concave curves with a ball turning tool with the tool bit extended beyond the pivot point.

Brian Oldford16/05/2019 08:16:33
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549 forum posts
4 photos
Posted by Michael Gilligan on 15/05/2019 20:49:43:

With those quantities ... Casting might actually be a realistic proposition

H&S legislation limits what can be done in the UK, but India does a lot of Brass.

MichaelG.

.

As a patternmaker I find no shortage of brass foundries. I'm always geting small runs of broadly similar bits cast. Once  polished they'd be virtually indistinguishable from the originals. PM me if it helps.

Edited By Brian Oldford on 16/05/2019 08:18:02

Edited By Brian Oldford on 16/05/2019 08:18:58

Michael Gilligan16/05/2019 09:06:16
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13827 forum posts
603 photos
Posted by Brian Oldford on 16/05/2019 08:16:33:

As a patternmaker I find no shortage of brass foundries. ...

.

That's good to hear, Brian yes

MichaelG.

Paul Lousick16/05/2019 10:15:15
1151 forum posts
492 photos

Mick,

Making special tools (form, ball turning, CNC, casting, etc) seems to be a lot of work for only 4 plates. Turn the middle and the outer edge of the plate and do the curved section by hand by adjusting both the X and Y direction of the cutter at the same time. It does not have to be precision work and you can smooth up any discrepencies with emery paper. Use a cutter with large radius tip for the free hand work. Cut a profile from cardboard to check the shape of the curve. Then part off the plate from the stock bar.

Paul.

Michael Gilligan16/05/2019 10:43:20
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13827 forum posts
603 photos
Posted by Plasma on 15/05/2019 20:32:09:

At first I need 4 in number but bearing in mind the house has in excess of 365 rooms, each with at least two doors (state rooms even have false doors that do nothing but achieve symmetry) I think I may be making a few more.

.

Paul, ^^^

Four ... maybe going on hundreds

MichaelG.

Perko716/05/2019 11:11:44
278 forum posts
23 photos

Original probably stamped, but would metal spinning over a suitable former be a better solution? I know very little about it other than what I've read in some books but it seems like a possibility.

Plasma16/05/2019 11:26:22
331 forum posts
41 photos

Definitely not spun or pressed on the original.

Paul I am fancying your idea, I have one of Eccentric engineering Turnado turning systems for free hand sphere turning and I think I may be able to utilise it in this project

I will let you know how I get on and the results .

Many thanks

Mick

Brian Oldford16/05/2019 11:29:05
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549 forum posts
4 photos
Posted by Plasma on 16/05/2019 11:26:22:

Definitely not spun or pressed on the original.

Paul I am fancying your idea, I have one of Eccentric engineering Turnado turning systems for free hand sphere turning and I think I may be able to utilise it in this project

I will let you know how I get on and the results .

Many thanks

Mick

Looking at the unseen face the originals definitely look sand cast. Everyday stuff.

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