Metal wallet/money clip Failure! 20 pics

Discussion in 'DIY Gear & Mods' started by Reverence, Nov 18, 2017.

  1. Reverence

    Reverence
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    So I was working on making a metal wallet/money clip. Like a big money clip to fit my CCards and money. I decided to use the metal from an old saw that I haven't used in a long time. You can see parts of the saw in some of the pics. I started out making a paper template then stenciling it on to the saw. My first attempt I tried to bend up the side tabs by hand. Didn't work :( Then I decided to do it right.

    First I annealed the metal so it would be soft and bendable. (heat it up and let it cool very slowly)

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    Then I cleaned up the edges and made sure the dimensions were correct. You can see the paper stencil in the pic

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    Then I started to make the die. I was going to press it so all the tabs would be bent up correctly. You can see the original failed attempt at the top.

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    Here it is all shaped up. Then I cut a hole in the middle, so I could slide the cards out.

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    I cut a piece of metal that is the same size as a credit card. I also made the piece that it would be pressed into.

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    Then I pressed it in using a vice.

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    It came out great. I tested it with a card.

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    Time to bend the top, so i build a little jig.

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    It was going good. A little crooked, but I tested it. Looked good.

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    BUT, then it happened. When I was trying to straighten it, I heard a crack. All that was left was to straighten it, heat treat it, and clean it up.

    Here's the crack :(

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    Damn! oh well. I have enough saw blade left to make another. I'm not sure if I will.
     
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  2. mctacticool

    mctacticool
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    If you do make another try bending it around a piece of roundbar, that might help with the cracking...
     
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  3. Reverence

    Reverence
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    I did. You can see the little jig I made to help with bending down the clip part. There's a round bar that I was bending the clip over.

    I already bent the 90 degree angles. I really wanted the bottom edges to be sharp. So the cards would fit nicely. I was in the process of bending the clip part to make it square and straight. The tweaking of the clip put too much stress on the sharp bend.

    I guess I could have used a map gas torch at that point. It would have made the bending very easy without stressing the other bends.
     
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  4. mctacticool

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    Oh yeah, i missed that... Then heating before tweaking should be the way to go...
     
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