< Smokebox 2 >
The dart to fix the smokebox door is made from silver steel. The shaft part and the triangle part are cut individually and silver soldered together.
The shaft part is cut square by endmill. Note a square block fixed on the opposite side of the shaft in order to rotate the shaft in every 90 degrees step.
This is the rod handle to rotate the dart with the square hole. This also made by silver steel two parts. The rod is slightly tapered. The square hole is drilled and finished by a fine square file.
The round handle is cut from a silver steel round bar. Before cutting, I prepared a home made cutter to finish the front face of the job. The round handle is cut as follows.
Chuck a round bar and turn front profile of the handle. Here the home made cutter is employed to cut a recess for the spokes. After that, part off and soft solder on a steel flat bar.
Set the flat bar on the rotary table. Drill and mill the windows between the spokes.
In order to finish the backside, I prepared a fixture as the first photo. Mount the job with the bottom facing outward and turn the front profile as same as the first step. And then the spokes appear. Note a small pin on the fixture to prevent slip of the job in the fixture.
The fixed side of the smokebox door hinge, that is the hinge brackets on the smokebox front ring have a complicated shape. They are made from a silver steel square bar. The procedure is as follows.
Fix the blank bar on a steel plate and cut horizontal profile by drilling and milling. The top and bottom parts with mounting holes will be sawed off finally.
Turn over the job on the plate and set the plate on the rotary table. Drill new mounting holes inside the current holes. Cut curved profile of the base part of the bracket. The curve is along the smokebox outer circumference.
Here saw off the top and bottom original mounting holes. Fix the bracket with new mounting holes and finish the top and bottom profiles around the holes.
Finally, set the bracket vertically on an angle plate. Drill the bearing hole and cut round profile around the hole. Note the bracket is mount firmly with a rectangle bar crossing the bracket. After that, turn over the bracket and finish the opposite bearing hole.
Regarding the mounting holes on the smokebox front ring, I accidentally opened four holes at one millimeter lower point than the design. I recovered it with opening larger holes in correct positions by end mill and silver solder four bushes made from a gunmetal round bar.
The hinge brackets fixed on the smokebox front ring. The holes are straight holes and the brackets are fixed by screws and nuts.