Making Chipboard End Discs (The Easiest DIY Way)

[cmjlab]

I needed a few more end discs today, and though buying them isn't to awfully expensive, it's nice to be able to knock out a quick 60 or so when you need it!  

I used an adjustable cutter sold by Harbor Freight for ~$25.00.  Sharpened the blades and re-hardened and tempered them with a blow torch and an oven. I used an angle grinder to grind down the center pivot piece, and voila, end discs cutter.

With a drill press set on medium speed, and x5 chipboard sheets taped together, I knocked out x60 2.5" end discs for 3" shells in approximately 90 seconds. Also works for nominal 4"-6" discs and down to 1.5".  I just use punches for anything smaller.

[MicroGram]

Nice! I keep meaning to buy one of those.

[dlking59]

Now I know what to use my drill press for. Bought new but haven't used it yet.

[Zumber]

I do have such drilling machine. Cool Idea...!!👌

[Guest]

I have the same adjustable cutter from the same place. They're a bitch to get set up evenly, but once you do get it set up for a job, it's almost better to buy another for the next job than to try and set it up again. 

But when you need one, there's nothing like it.

[cmjlab]

To get them aligned easier, I poke a hole in a piece of chipboard to use for the center pin, then get one blade to the right position for the size disc I am making and lock it in.  Then I chuck it up in the drill press and spin the locked blade to score a circle to use for aligning the 2nd blade in place.   

 Once set, I score "witness marks" to save where exactly they need to be for a given size.  With that being said, I do have x2 of them since most of what I make is 3" and 4", I rarely have to move them for 5" and 6" discs.  Plus I make a bunch when I have time, so I don't have to worry about it for a year.

Edited December 26, 2023 by cmjlab