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AlexAndChristine  > Home Machine Shop > Lathe > Daruma++ bolts
DARUMA bolts are used with Honjo fenders to mount the fender to the bicycle frame. Mark Vande Kamp is building a rack for his bike and the rack needs to mount to the same point as the fenders. A goal is to make the rack remove with just a couple of bolts. I made these replacement Daruma bolts which have an extra threaded portion for holding the rack. There is a good photo of a normal Daruma bolt here (linked from Jitensha's page on Honjo fenders):
http://www.jitensha.com/eng/images/lngshrtdrmascrws.jpg

It is a pretty good simple lathe project, so I thought it would be a good thing to document. It has facing, turning and drilling and uses both the 3-jaw and 4-jaw chuck.

The bolt is made of 303 (free machining) stainless steel. This was my first experience using it, it machines pretty nicely.
Gallery pages:  1  2  3  >  
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AlexAndChristine > This is the first bolt that I made, shown as a preview of what we are making in this series.

At the bottom it has a M5 male thread which goes into the frame.  There is a cross-hole that the fender stay goes into.  The stay is secured with a special washer that isn't shown here.  At the other end there is a M5 female hole that the rack mounts to.  This is what makes it different from a normal Daruma bolt.
AlexAndChristine > The first job is turning down the OD of the stainless steel to 7.7mm (the diameter of the original Daruma bolts).  This diameter is important because the bolt fits into a recess on a special washer.
AlexAndChristine > More turning.  The 303 stainless makes pretty small curls (especially compared to aluminum where I get curls that are yards long).
AlexAndChristine > I'm using a Sharpie to mark the location of the step for the external threads.  This isn't a precision measured length, so the wide sharpie mark is okay.
AlexAndChristine > Cutting the stepdown for the external threads.
AlexAndChristine > All of the turning operations are complete.
AlexAndChristine > I'm threading the 5mm external threads with a die.  Note that I'm not doing this under power!  The lathe chuck just makes a very nice round vise.
AlexAndChristine > It is threaded, time to cut it off of the stainless rod.

The tubing block there is one that I made on my milling machine.  It can hold 3/8" or 1/4" tubing depending on the orientation.
AlexAndChristine > After it came off.  You can see that it isn't a very clean cut, we'll fix that on the lathe.
This is the first bolt that I made, shown as a preview of what we are making in this series.

At the bottom it has a M5 male thread which goes into the frame. There is a cross-hole that the fender stay goes into. The stay is secured with a special washer that isn't shown here. At the other end there is a M5 female hole that the rack mounts to. This is what makes it different from a normal Daruma bolt.
 > This is the first bolt that I made, shown as a preview of what we are making in this series.

At the bottom it has a M5 male thread which goes into the frame.  There is a cross-hole that the fender stay goes into.  The stay is secured with a special washer that isn't shown here.  At the other end there is a M5 female hole that the rack mounts to.  This is what makes it different from a normal Daruma bolt.
This is the first bolt that I made, shown as a preview of what we are making in this series.

At the bottom it has a M5 male thread which goes into the frame. There is a cross-hole that the fender stay goes into. The stay is secured with a special washer that isn't shown here. At the other end there is a M5 female hole that the rack mounts to. This is what makes it different from a normal Daruma bolt.
Camera: Fujifilm (Finepix F10 ) |
More details: exif |
Original size: 2848px x 2136px |
Current: 400px x 300px |
Other sizes: Small • M • L • O • save photo |
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Keywords: bicycle metalworking lathe
Gallery pages:  1  2  3  >  
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