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Introduction Edit

It is important to get the holes in the washers and in the field-frames aligned properly. The easiest way to do this is to create an accurate template for marking and/or drilling the holes. This article describes one way of making such an template from steel. There is another article that describes the manufacture of a plywood template.

The process step by step Edit

First make a CAD model of the washer's rim with a sufficient number of holes. Next glue it to a piece of thickish (3-4mm) steel:

Making washer rim drilling template - 01

Mark the places of the holes with a punch:

Making washer rim drilling template - 02

Drill the holes on the rim and in the middle. The purpose of the middle holes is to remove as much material as possible:

Making washer rim drilling template - 03

Remove the piece of steel in the center:

Making washer rim drilling template - 04

File the center round:

Making washer rim drilling template - 05

Making washer rim drilling template - 06

Expand the center hole until the washer core fits snugly into it:

Making washer rim drilling template - 07

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