BazookaMedic
Version: 1.0
Released: 12-26-2006
Contents
Disclaimer- The Obvious
Safety
Materials- What you need
Preparing your Stock
Attaching the Templates
Proper use of a File
Proper use of a Bench Grinder
Proper use of a Dremel Tool
Milling your Picks to Shape
Finishing your Picks
Tension Wrenches
Disclaimer
Obviously I have to protect myself from some ignorant people out there so here we go. I BazookaMedic am not responsible for the result of your partaking in the activities described in this instructional manual. You can do what you please with this manual. I publish this with the intent for anyone who wants it to have it.
Safety
The use of tools to make your picks obviously carry dangers. A bench grinder the most commonly used tool for this can kill you if misused. Things to note when using a bench grinder:
• Do not grind on the side of the wheel as seen in picture a. the wheel will shatter and sever your limbs and fingers.
• Always wear safety goggles. A bench grinder tends to flick tiny sharp shards of metal out and you do not want to be hit in the eye.
• Wear long sleeves. Same reason as above.
• Have a clean work area. It makes life easier and safer.
• Watch your fingers. Grinder burn hurts. And you run a risk of taking your finger off.
Materials
• Bench Grinder (optional but will make your results fast and good.) – A small cheap 6 inch Ryobi model or delta will do very well.
• Tri-file- for finishing work ang cutting angles you can not do on the grinder.
• Flat file- For finishing your picks.
• Finishing file- for deburring.
• 220-1200 wet dry sand paper- for finishing your picks.
• Cup of cold water-for quenching.
• High Carbon Steel Hacksaw blades- Pick material.
• Windshield wiper inserts- tension wrench material.
• Lighting source
• Templates
• Krazy glue- for securing templates to blades
• Cardstock-for the templates.
• Scissors- To cut out the templates.
Preparing your Stock
The first thing to do is start with your material your picks will be made of. Start by taking 5 inch segments and snapping the blade in half. You can get two full size picks out of one 12 inch blade. Next take some 220 grit sand paper and sand all of the paint off. This will save your fingers later. Then go on to the next paragraph.
Attaching the Templates
Take the templates provided at the end of this manual and print them off on the cardstock. This paper is tougher and more durable than regular paper. So next, cut out the templates as close as you can to the outline of the pick shape. The closer the better quality your pick will be. After you have the templates cut out will want to glue them to the hacksaw blade. Coat the blade and back of the template and press it down on the hack saw blade. Let that dry for 5 minutes for maximum durability. Then apply a coat over the top of the paper and get the sides for waterproofing. Again let dry 5 minutes.
Tool Choices
At this point you have two options, A. Bench grinder and file, or B. File only. If you are using a file only to produce your picks, you will not need the coldwater to quench your pick in. C. Dremel tool. Refer to the next paragraph for procedures with a file. If you go with a bench grinder or a Dremel, you will need your safety goggles, Long sleeve shirt, and the cup of cold water to quench your workpeice in.
Proper use of a File
A file will only cut into the metal if it is used at an intersecting 90 degree angle as seen in photograph A. Regardless of which option you take you will use a file. A file used to finish the pick removes microscopic cracks and gives a better surface. This provides more sensitivity and greater strength in your pick.
Use a trifile as in photo b.
A
B
Proper use of a Bench Grinder
A bench grinder makes the production of picks faster, easier, and more accurate if used properly. Make sure you have on your safety goggles, long sleeve shirt, and your cold water before you start. A bench grinder does have a tool rest on it. I suggest using it as it helps out with getting a flat edge. More experienced people can “free hand†their picks. I do not suggest this as the reader being new to the procedure will most likely mess up their pick and their fingers. You will always want to grind in short bursts with a maximum of 3 seconds grinding before you quench your work piece. You want to give your work piece a quick dip into the cold water after the burst of grinding to cool the metal down. If your pick changes color and “sizzles†when it hits water you ruined the temper and your pick if you do not have a blow torch. And never grind on the side of the wheel. It will shatter and kill you photo A. Finally do not grind the blade as shownn Photo B If you do it will kick the blade back at you with very painful results.
A
B
Proper use of a Dremel tool
The using of a dremel tool allows you to cut closer angles than you ever could with a bench grinder. You do need to have the quench cup with a dremel also. The best method I have found is to have multiple grinding wheels and cutoff wheels. I find that cutting chunks away with the cut off wheel to get the pick to a mingle size, and then grinding with the grinding attachment. Then finally finish them with hand files.
Milling your Picks to Shape
Now that you have learned the proper and safe usage techniques for your tools, and you have your stock prepared as in the first two paragraphs- you are ready to start your picks.
With all 3 methods your objective is to make the metal flush with the paper. You will grind, file, or cut your way there. When you are grinding or cutting make sure to only do so in short 2-3 second bursts and quench the pick. Remember let the speed of the tool do the work. It produces better quality tools and prolongs the life of your grinding wheel, or cutting disc.
Once you have the rough shape of your pick, you will want to take your flat file and file the edges the rest of the way to make them flush and smooth. For angles use the tri-file. This not only gives your picks more sensitivity, it also increases their strength. Now you should have a nice looking pick that needs finishing work on its surface.
Finishing your Picks
The key to quality picks is the finishing. It is simple but takes some time to do right. You should have your silicon- oxide wet/dry sandpaper at this point. The goal is to produce a mirror finish. Here comes the fun part.
You will want to start with 300 grit if you removed the paint with 220grit as stated in the very first paragraph. Once you get the scratches out from 220 grit, move up to 400, repeat and continue to 1200 grit.
For the 1200 grit paper sand with it dry until you do not see any scratches. From their wet your work piece with water and sand more. Repeat this 4 times. Once you have done this your pick will be as shiny as a mirror.
Tension Wrench Construction
Tension wrenches are very important. With out them you can not pick a lock. The procedure for making them is simple as you will only need some pliers with cutters in them, and some windshield wiper inserts. To acquire windshield wiper inserts you can check the garbage bins outside of auto parts stores, ask a mechanic for some, check your local junkyard, take your own when you replace wiper blades, check oil change place.
The wiper inserts are made of very durable stainless steel. You can bend your wrenches to shape with your pliers and they will still maintain their original integrity. The following is a list of basic tension wrenches you will need and how to make them.
Standard Tension wrench
Material: 3 5/8inches of windshield wiper insert.
Crafting: At 3 inches make a 90 degree bend and you completed your wrench.
Twisty Tension wrench
Material: 3 5/8 inches of windshield wiper insert.
Crafting: At 3 inches make a 90 degree bend. Then about ½ inches below the 90 degree bend, twist the wrench 90 degrees. You now have a twisty wrench.
Double wrench
Material: 41/8 inches of wiper insert.
Crafting: At 3 inches bend the wrench as you would for a standard wrench. Then 3 inches below your first bend, bend another 90 degree angle. This one should be smaller than your first bend.
Spacer Tension wrench
Material: 5 inches of windshield wiper insert.
Crafting: At 3 5/8 inches make a 60 degree bend. Then from that bend make another 60 degree bend upwards ½ inch from the first bend. Then bend a 90 degree angle 1/2 inch from that bend.
Templates
