Whippet Brake Lever


 

In this tour of my shop, I’ll show you how the brake lever was created by copying the original in the photo below. In all, it took about 2 days.

1888 Whippet Replica right brake lever

I wanted to carve it from solid, with no welding. I should have used a 1X3″ steel flatbar, but only had 1X2″ on my shelf. So, I cut a notch.

1888 Whippet Replica right brake lever

This is my big torch, with a “rose-bud” tip.  It generates a lot of heat.

1888 Whippet Replica right brake lever

The bar is supported in the arbor press and heated.

1888 Whippet Replica right brake lever

It gets hot . . . it gets bent. That’s Valentino Rossi on the door poster.

1888 Whippet Replica right brake lever

After cooling, the high spots are machined off.

1888 Whippet Replica right brake lever

I took the photo (of the brake lever) to a photocopier, and enlarged the image to life-size. I glued it to cardboard and cut it out. The steel was painted with layout dye, and the shape scribed onto the steel.

1888 Whippet Replica right brake lever

Vertical bandsaw was used to cut out the shape.

1888 Whippet Replica right brake lever

Here, I’m using a Makita angle grinder to start shaping the “hand” end of the lever.

1888 Whippet Replica right brake lever

A little hand file work gives the final shape.

1888 Whippet Replica right brake lever

An endmill with a rounded nose hollows out the back of the handle. The red felt pen marks help define the middle section of the lever.

1888 Whippet Replica right brake lever

A Spiral Roll mounted on a high speed grinder smoothes the shape created on the mill.

1888 Whippet Replica right brake lever

Bandsaw rough cuts the top and the bottom.

1888 Whippet Replica right brake lever

And a file and emery cloth make smooth.

1888 Whippet Replica right brake lever

The other end of the lever needed a 5/16″ thread, and i wanted it to be right in line. The lever end got C-clamped to a fixture on the edge of the mill table.

1888 Whippet Replica right brake lever

I thought the end of the lever needed to be round, so the lever got threaded onto a 5/16″ stub, and turned it down to 5/8″.

1888 Whippet Replica right brake lever

Brake lever is now finished except for bead blasting, electroless nickel plating, and installation.

1888 Whippet Replica right brake lever

Thanks for coming on a mini-tour of my shop. Until next time,

Paul Brodie

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