31 May, 2010
Those are the beginning of my goggles. Looking back at them, I could probably have planned them out a bit better, but for what I had to work with I'm rather happy with how they're progressing. I even got out all the metal burrs out so that they don't poke little splinters into my face anymore! That being said, though, the steel is a bit uncomfortable to wear right up against my eye sockets, so I'm thinking some kind of padding is in order. I've been thinking maybe I ought to add some rolled flannel fabric around the rims, but then I'm not exactly certain how I'm going to get it to stick to the steel. Hot glue feels like cheating, but it may be my only option. The heat gun that I used to braze the steel ribbon to the steel pipe would set the fabric on fire, so unfortunately that's out.
There will be no nonfunctional gears on my goggles. Instead, I intend to add some iris mechanisms to both eyes (once I can bribe my way onto someone's CNC machine, anyone have some good cookie recipes they're willing to share?), green lenses, and at least 1 laser mounted on the side. I probably ought to also make a headband at some point.
How to make Really Heavy Glasses Frames:
1) Procure 1 3" steel pipe nipple, diameter to your specifications (I used 1.75"), with both ends threaded.
2) Sit down with calipers and devise needlessly complex formulas to make perfectly even angled cuts to get scalloped eye pieces.
3) Clamp the pipe to a firm surface.
4) Attempt to cut it with your Dremel, realize it will take about 7h to cut through it that way.
5) Get someone to teach you how to use the much more powerful angle grinder.
6) Attempt to use the angle grinder.
7) Observe that angle grinder has obliterated all planning of step 2.
8) Observe that angle grinder has kicked up a fine steel dust all over your face. Remove safety goggles and ponder your likeness to a raccoon for a couple minutes until you observe the twang that all the flying sparks left on the wall.
9) Continue angle grinding, creating several large burrs.
10) Finish cut.
11) Clamp down 1 of the eyepieces, burr side out. Change angle grinder head from cutting to grinding and apply to burrs. This may induce shrapnel. Eye protection is very important.
12) Get rid of all large burrs with angle grinder, then use Dremel to remove finer burrs.
13) Discover Dremel's polishing capabilities. This will set you back about an hour, but it won't get you much shinier.
14) Discover the 17 small burrs you missed. Go back over with a Dremel.
15) Cut slots for the 1/4" 14G steel ribbon. Thread precut lengths of steel ribbon through holes, manipulate with pliers into desired shape.
16) Rig up a vice on something fireproof.
17) Apply heatgun until goggles begin to glow, clamp down ribbon with long-handled pliers and apply some sort of binding flux*. You may have to do this sequentially, in which case it should be noted that the heatgun does not cool down rapidly.
18) Continue until all pieces are in place.
19) Be satisfied with progress for now.
20) Write self-deprecating blog post later about project.
*Yes, strangely enough this part where I was quite competent, but not with the angle grinder.