18 replies to this topic

[Guru4tru]

How to Snag Proof Your Rev. Handles

Let me say right off...”It’s a whole lot easier to buy them!”...but, then...what else are you doing on a windless rainy day?!? (If you don’t own a Zen!)

Get an aluminum rod with about the same OD (outside diameter) as your Rev. handles. And cut (4) pieces off it with a hack saw, so they are about 1” long. (The actual length isn’t important nor do they have to be the same size at this stage...just get them sort of close.) I used a solid aluminum rod from an old antenna I found.

This is the hard part...drill a 1/8” hole in the center of each piece about 1/2"+ deep. (Note: This can be done after the piece is finished, but I figured if I was going to screw anything up it would be in drilling the hole, so I put that at this stage so I wouldn't be messing up things I put work into.) I did it my hand, but if you have a drill press-or-know of someone who does—that’s the way to go...or...make a bunch of spares, like I did, because the holes of some were off center (see picture).

Now stick the piece of aluminum rod in your drill bit, hole facing out, so it is sticking out of the drill 1/4" (measured) and tighten it in the drill bit. Lay you drill on its side at the edge of a table with the aluminum piece sticking over the edge. Turn your drill on and place a file against the aluminum piece that is sticking out. The file will start shaving down the aluminum rod smoothly. The important thing here is to stop every now and then and check to see if it’s small enough to fit into the "debured" end of your Rev. handle. When it is, then do the next (3) the same way (see picture).

When all pieces are finished and each fits in the ends of the handle (a little slop is OK), then mark each piece 1/4" from where the size of the aluminum changes going toward the thick end (see picture).

Now put one of the pieces into the drill bit, with the small end inward this time, and tighten it in the drill with the mark right at the edge of the face of the drill. Lay the drill down like before and turn it on and put the side of hacksaw blade against the face of the drill and the cutting edge on the aluminum. Now with the drill on, cut through the piece by moving the hacksaw back and forth, like you would normally do, except little pressure is needed (see picture).

After all (4) pieces are cut to size go back and lightly file smooth all edges and, using a larger drill then before, chamfer the edges of each hole by hand on the front and back sides.

Tie a knot in each leader line, that you have already made up, about 2 1/2", or so, from the end that will be going into the hole. Draw the lines through each hole and pull tightly up against that knot, as you tie a knot in the other end. This will insure that there will be no movement between the leader line and the metal…the knot will be taking the stress, not the line against the metal. Put a drop of super glue on the knots.

Holding the aluminum part against the Rev. handle so that the holes in the handle are at the same level as the top knot in the aluminum piece and mark the handle as to where it will be cut, so the point at which the line comes from the handle is the same as it was before--after the pieces are inserted, which would be cutting slightly below the holes that are already in the handles. Cut the handles off with a hack or band saw and de-bur all the edges. Using a two part epoxy, glue the aluminum pieces into their proper places on the handles. Note: There will be a slight pressure within the handle's tube that will cause the ends to slide out if they aren’t held in place till the glue cures.

And that’s it! (See picture)

Keep It Up!
Duane

PS Disclaimer: Making this is at your own risk. I will not accept any responsibility for damages caused to yourself, your kites, or your neighbor’s kids!!

[Baloo]

Absolute proof that a picture paints a thousand words.

And that the proverb "Wet / No wind Days, make idle hands produce interesting and useful additions to youe Rev kit"

Way to go Duane

"Keep it up" to quote some famous bloke.

[Guru4tru]

Thanks Baloo!

I have another set of handles that I “snag proofed”. Their a little more exotic......

I used some elongated beads I have, that I used to make malas with. There made out of the human bones of a long departed Japanese Zen Master (道元禅師). The good thing about using bone beads is that they can be filed by hand and they already have a hole through the center, which makes it a lot easier to work with. And being the bones from a departed Japanese Zen Master...well...why not!! I figure I need all the help I can get out there!! heehee!!

Keep It Up!
Duane

[BillLamm]

Guru4tru, on 08 April 2010 - 02:10 PM, said:

Thanks Baloo!

I have another set of handles that I “snag proofed”. Their a little more exotic......

I used some elongated beads I have, that I used to make malas with. There made out of the human bones of a long departed Japanese Zen Master (道元禅師). The good thing about using bone beads is that they can be filed by hand and they already have a hole through the center, which makes it a lot easier to work with. And being the bones from a departed Japanese Zen Master...well...why not!! I figure I need all the help I can get out there!! heehee!! snagZen1.jpg

Keep It Up!
Duane

Well now you will have to order a Zen Kite....

[Guru4tru]

Hi Bill,

"No!"...heehee!...I just made up the story about the bones of a dead Zen Master...that's funny!

They are bone beads though, but probably from the part of the steer that didn't reach my table when I ate out last week!!

Yes...getting the ZEN...is located "way" back in my mind as, "Things to do before I die!" But, I have to get a "Full-Vent", to work with the "more wind" times...&...let the "less wind" times pass for awhile, at least until I learn how to fly with the wind first!! heehee!


Keep It Up!
Duane

[Baloo]

You could always, possibly be the first to ask for a Mega Vented Zen

[Guru4tru]

Keep It Up!
Duane

[BillLamm]

I like your no snag method... I have solid 3/8" aluminum that I drilled a hole from the ends and a slightly bigger hole from the side so I can hide a knot in the bigger hole and have the same effect... your way is easier...

[Guru4tru]

BillLamm, on 09 April 2010 - 05:36 PM, said:

I like your no snag method... I have solid 3/8" aluminum that I drilled a hole from the ends and a slightly bigger hole from the side so I can hide a knot in the bigger hole and have the same effect... your way is easier...

Hi Bill,

What would have probably been easier, although I didn't think of it at the time (because it was too simple, I guess), would have been to just cut a piece of aluminum rod about the same size as the inside diameter of the handle tube and, maybe 1/4" to 3/8"long...drill a hole in it, (tie the leaders to it) and then epoxy it in place flush with the end of the tube.

But, that's too simple and I wouldn't have been able to take all those instructional pictures!! heehee!

Keep It Up!
Duane

[Reef Runner]

Hey Duane,

Looks great, and gives me some real ideas, for sure. I'm assuming, that in your original description, of your creative process, when you referred to putting the piece into the drill bit, you actually meant, that you were putting it into the drill "chuck". Is that correct?

Not meaning to be critical in any way, and for sure, I realize that everyone doesn't have access, but these inserts could be made very quickly, and with much greater accuracy, on a metal lathe. If you know someone that is skilled with a lathe, you could probably get them to make you a hand-full of those inserts, for little of nothing.........eh? Never know when you might need a spare, or another set.

I only have one question - What do you do, if you need to replace the pigtails? Just curious, because if I understood completely, once you epoxy the aluminum inserts, into the ends of the Rev handles, you can no longer access that inside knot, which holds the pigtail in place? Am I correct, or did I misunderstand your process? I suppose you could use something very strong, that you know will never wear or break?

Again, you have surely given me some real food for thought, and I think I can hear a lathe turning, right now............

Thanks for sharing your idea..................