D5 Hammer Production

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Ihateplastic

Trad climber

It ain't El Cap, Oregon

Sep 10, 2010 - 01:20am PT

Cap'n... Of course, but the hammer pick still takes abuse from general bangin around (that's what I meant earlier, NOT placing the heads) and I guess I see that wall as just a tad thin. I am probably being a big baby...

Mungeclimber

Trad climber

sorry, just posting out loud.

Sep 10, 2010 - 01:34am PT

D5 lives!

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Sep 10, 2010 - 02:04am PT

Made some good progress today on drilling the 'biner holes. This keeps up and they'll be done some time this decade. ;)

Settled on:
1) Face mill with 3/8 endmill in drill chuck to create a flat surface to work on.
2) Center drill to start hole.
3) Drill all the way through with 1/4" drill bit.
All the heads get finished to this state before starting on the next step.
4) Drill/Mill with a 19/32 endmill in a collet.
The endmill is used because of the side loading created by the angle of bottom and top of the pick end. Drill bits are longer and are designed to drill down. Drills tend to wander side to side on surfaces not perpendicular to thier direction of travel.

Yeah the biner hole sidewalls look kinda small. Especially at the top. It gets more meat down farther because of the taper in the vertical axis. I had the same thought as you initially about the thin part but field testing shows this to not be an issue.

D5 does live!

healyje

Trad climber

Portland, Oregon

Sep 10, 2010 - 02:21am PT

Theron, I need to give Lewis a shout as the final handle samples haven't arrived yet (unless he shipped them direct to you...).

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Sep 10, 2010 - 02:23am PT

I don't have them. Give him a shout.

Clint Cummins

Trad climber

SF Bay area, CA

Sep 10, 2010 - 02:31am PT

I wondered about those seemingly thin walls as well - thanks for explaining.
It looks like a very slow/expensive series of steps to make the biner hole.
So it seems clear why John dropped this part of the original A5 design.
Have you considered (say) a $100 version without hole, $150 with hole?

Lambone

Ice climber

Ashland, Or

Sep 10, 2010 - 02:35am PT

nice

Acer

Big Wall climber

Sep 10, 2010 - 02:50am PT

Is the price still coming out to be the same??

http://www.supertopo.com/climbing/thread.php?topic_id=151177&tn=260

Costs per each Hammer:

Deburr of Forging Flash: 7.00
Milling of Hammer Face: 5.75
Drilling of Carabiner Hole: 6.00
Heat Treating: 1.47
Sandblasting: 1.05
Assembly: 9.50
Anti Corrosion Dip: 0.65
Drilling of Handle for Leash: 0.75
Logo Removal: 2.00
Subtotal: 34.17

Previous Costs:
(2) Stainless Steel Tangs: 2.92
Forging of Hammer Head 16.45
Total: 53.54

Remaining costs:
Leash w/ Ring-Russ?
Handle-Joseph?

Assembly might be a little high but I am not sure how it will work out. Reading John's notes it seems pretty involved so that's how I quoted it.

Acer

Big Wall climber

Sep 10, 2010 - 02:55am PT

Just a note on the side walls to the pick of A5 and D5 hammers.

They are plenty robust to do the job. They are all like that. And not all were exactly on center.

You can see I have had my hands on a few. I would say that I have handled 1% of the A5 hammers.

http://www.supertopo.com/climbers-forum/1264334/Kids-Babies-and-Climbing-ST-needs-a-little-LOVE-Again

healyje

Trad climber

Portland, Oregon

Sep 10, 2010 - 02:59am PT

Acer, we'll be sorting out actual vs. estimates in the near future when we have the final actuals and will post them up once we have it. I want to really make sure Theron doesn't end up short in any way after all his hard work on the project.

Acer

Big Wall climber

Sep 10, 2010 - 03:06am PT

Expected for sure.

Not to forget that the final cost includes the donation that was part of the deal with this project.

healyje

Trad climber

Portland, Oregon

Sep 10, 2010 - 03:33am PT

Definitely haven't forgotten that part of the deal and am looking forward to the day the project can send Conrad a check for the Alex Lowe Charitable Foundation and a few hammers for its Khumbu Climbing School Program. We'll also be gladly accepting and passing along any additional donations beyond the final price of the hammer should anyone choose to contribute further to the foundation and school.

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Sep 16, 2010 - 09:26pm PT

Biner holes are done. Logo and chamfering of holes are up next. I think that facing the heads and drilling the biner holes were the cruxes. No scrap so far that I know of. I'll double check. Four mills down for facing and five down for doing the biner holes. Not too bad.

I'll update soon on the rest of the work being done. I hope to be devoting more time next week to this project.

SteveW

Trad climber

The state of confusion

Sep 16, 2010 - 09:58pm PT

Thanks for the update, Theron!

Thorgon

Big Wall climber

Sedro Woolley, WA

Sep 16, 2010 - 11:08pm PT

Labor of love!

Hammers rule,
Thor

healyje

Trad climber

Portland, Oregon

Sep 16, 2010 - 11:34pm PT

Sent Lewis an email on the final handle samples and didn't hear back. Will give him call him tomorrow.

healyje

Trad climber

Portland, Oregon

Sep 23, 2010 - 08:27pm PT

A dozen final handle samples are on the way from Tennessee!

T Moses

Big Wall climber

Paso Robles

Topic Author's Reply - Sep 23, 2010 - 11:58pm PT

I received the material for the tangs on Wednesday:

I had to get a whole 48 x 120 sheet but it was the same for a half sheet from a more local supplier.

Heads are coming along nicely:

The holes are all drilled. They are also chamfered and the sharpening of the pick has commenced:

The logo is giving me some problems. I can't just hammer strike the punch and have it give an acceptable impression in the head. I might mechanize this with a fixture in a punch press.