Ive been making custom springs for my 16 tooth ratchet and dog kit for the 9500SS, so I figured Id take this opportunity to write up a how-to on winding your own springs from music wire or spring wire. I used 0.021" stainless spring wire for these springs because its the same size as the wire on the original spring.
Things you will need: wire, mandrels, needle nose pliers, and a way to hold the wire while you are winding it. I use a bench vise with angle aluminum between the jaws to apply tension to the line when winding. The mandrels will need to be smaller than the desired diameter of the spring, because it will "spring" back.
I found that a t handle tap holder and a tap is perfect for holding and winding the spring. The gap between the jaws is perfect for holding the end of the wire, and the round shank of a tap makes a nice mandrel.
Picture 1: tap holder and tap, the sample spring, and a length of spring wire.
Picture 2: close up of the spring Im using as a sample.
Picture 3: piece of spring wire, with a 90 degree bend in one end
Picture 4: showing the gap between the jaws of the tap holder where we will put the bent end of the spring wire.
Once you have a 90 degree bend in the end of the wire, insert that into the gap between the jaws of the tap holder.
Then clamp the other end of the wire in the vise. You want to be able to pull the wire through, but it should take a good bit of force.
Apply tension to the wire, and start rotating the tap handle to wind the coiled part of the spring. Keeping heavy tension on the wire when winding helps keep the coils even, and reduces the spring back once you let off the pressure. The spring will unwind, and the coils will expand when you let off the tension, so you will need to wind more coils than on the sample. I had to go nearly 5 turns to get 3 coils without tension on these springs.
It takes trial and error to determine the size of mandrel you need, as well as the number of coils to achieve the desired result. Luckily its not hard, and spring wire is very cheap.
Once you have the coils right, cut it from the long wire you started with, leaving some excess on the tag ends. You will need the excess for making the extra features on this spring.
Once you have your coil completed, its time to start bending the tag ends. Use the needle nose pliers to hold the wire, and bend it over by hand. Bending more than once in the same spot severely weakens it, so try to avoid re-do's here.
You can see the stages of the bends on this end in these 3 springs.
Then we can move onto the other end. I marked where the small loop on the end should start, and clamped another tap in the vise to use as a mandrel. Using my hands, I pinched the wire around the mandrel with one hand, and used the other to bend the tag end around. Then I used the needle nose pliers to adjust the loop to the proper size.
Once both ends are bent to their final shape, trim the ends to length, and you are finished.
Priceless,
Thanx,
Leo
I have got some titanium wire that is very springy. Maybe I will try that. :)
Titanium springs must be the ultimate! :)
this site just keeps getting better.good stuff
Good idea with the tap and tap handle. I have a real spring making tool I use to make butt rings with but it does not do small springs.
NiTi wire would also be perfect for this situation! At a fraction of the cost of pure Ti wire.
Clear and useful instructions. Thanks.
VERY COOL . . . Excellent !!!
I don't want to HIJACK this thread, but I do have a couple of Documents on making Springs, etc that I would like to add to this thread.
ATTACHED . . .
Tight Lines !!!
PLUS, here is YOUR article in a form that can be DOWNLOADED by everyone . . .
Tight Lines !!!
gentlemen, thank you!
Quote from: alantani on March 25, 2015, 06:26:48 PM
gentlemen, thank you!
Alan,
For future reference, all I did was highlight and copy the text. Then, I pasted it into Word and saved it as a PDF file. Finally, I uploaded it to the forum, so everyone could download it, if they wish.
Tight Lines !
Thanks for sharing the info and pictures with us all...... The tap and taphandle Idea was great!!!!!!! wish I had seen this sooner????? Great Idea and shows how we can all help each other and be happy too!!!!!! gst.
From a guy who makes his own flying c's (me)
Superb topic on how it's done, bending wire by hand.
Great stuff thanks. I remember` making replacement TLD springs a long time ago.
I used mono SS trace wire and it works very well.
do you make them for a price? 1 need two for my newell C540-4.6. part # 3-315. Thanks
Thank you very much for showing this technique. The spring material I need is .021, and I have the taps and handle.
0.021 inch is about 100 pound test leader wire.
-steve
three se7ens thanks very clearly explained, many of us will make use of this post, cheers don.
Quote from: garyboland on March 31, 2017, 12:21:21 AM
do you make them for a price? 1 need two for my newell C540-4.6. part # 3-315. Thanks
Sorry, I only make what I need for my Spinfisher a/r kits.
Great write up , i need to make a couple springs . The question i have is there any one material better than the other , leader wire ,music wire ,spring steel ,something salt water friendly. joe
Quote from: oldmanjoe on May 23, 2017, 12:54:07 AM
Great write up , i need to make a couple springs . The question i have is there any one material better than the other , leader wire ,music wire ,spring steel ,something salt water friendly. joe
Music wire and spring steel are the same thing. Im not so sure about leader wire, but I suspect it doesnt have the same tight quality control over hardness and "springy-ness" as real spring wire.
I use the stainless spring wire found here. (https://www.mcmaster.com/#spring-wire/=17qtu4i)
Id be happy to send you some of what I have, the roll would last me a few lifetimes at the rate I use it.
Piano wire and spring steel will rust.
-steve
Awesome write-up. Thanks for the resource
Quote from: Three se7ens on May 23, 2017, 03:43:00 AM
Quote from: oldmanjoe on May 23, 2017, 12:54:07 AM
Great write up , i need to make a couple springs . The question i have is there any one material better than the other , leader wire ,music wire ,spring steel ,something salt water friendly. joe
Music wire and spring steel are the same thing. Im not so sure about leader wire, but I suspect it doesnt have the same tight quality control over hardness and "springy-ness" as real spring wire.
I use the stainless spring wire found here. (https://www.mcmaster.com/#spring-wire/=17qtu4i)
Id be happy to send you some of what I have, the roll would last me a few lifetimes at the rate I use it.
Thank you for the offer, I may take you up on that .. I am still testing what i have now .. thanks again joe
Excellent Triple 7!
I need to make a very small sping and will scale down the needed tools and give it a go.
Already have a lifetime supply of 4 different diameters of SS Spring wire that I use in another hobby.
While servicing a CS 501 last night, the spring vanished on me. Not having any wire, just wondering if I can use a pen spring and just re-wrap it to make it smaller and if it will work enough to be trusted temporarily.
Not really sure of the size you need, but if it's smaller than pen spring you may want to tear apart a Bic lighter ???
Swear I read about that somewhere before on here...or maybe I was just dreaming ;D
Brett
Bic lighter! even better I have some of those. Thank you very much, I feel much better now.
Thanks Brett, worked perfectly.
I had an anti-reverse spring jump into the ether and I made a replacement from a guitar string and it turned out well.
Actually, the bic lighter springs are slightly different than the scripto (cheapo) lighters-(ones i recommended)-the cheap ones at any convenience store.. just pry off chrome top, then remove flint wheel (spring is under the flint) before you buy one, look around the parking lot hehe....
Will Piano wire work? I have some for kingfish that could be put into "spring service"!
Quote from: Whit on July 17, 2018, 09:56:14 PM
Will Piano wire work? I have some for kingfish that could be put into "spring service"!
Given the correct diameter & temper for the intended use, yes.
Quote from: Whit on July 17, 2018, 09:56:14 PM
Will Piano wire work? I have some for kingfish that could be put into "spring service"!
True piano wire is spring wire, but solid wire leaders for fishing are may not be. The wire fishing leaders Ive tied do not react to bending like proper spring wire. It will likely work in a pinch, but Im not sure about its longevity.
Whenever someone mentions piano wire.
It reminds of the Jaws Movie.
That is where Quint got his wire leaders for sharking. ;)
https://youtu.be/9x-icUMAFYE
Piano wire is very hard with a lot of spring, but it is high carbon and will rust. If you can keep it greased and rust-free it works well. If it rusts it will weaken and stain everything. Piano wire can also be difficult to work with because it will crack or break if the bend is too sharp.
Stainless is more soft and malleable, but the chromium oxide that forms on the surface will protect it from corrosion. You may have to use a thicker wire to get the same strength and spring as with piano wire, but stainless is more stable and less trouble. Stainless is easier to work with too.
Both come in a pretty good selection of sizes.
-steve
Good write-up.
Coil springs are routinely made by machinists and I've made several on my lathe using regular Malin fishing wire for non-critical things (temporary). The trick is to get the right "springiness".
i use cigarette lighter springs to make anti reverse dog springs. just cut to size.
Quote from: Keta on March 23, 2015, 12:17:12 PMGood idea with the tap and tap handle. I have a real spring making tool I use to make butt rings with but it does not do small springs.
Do the butt rings match your butt plugs ;D ;D