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Old 04-12-2013, 03:45 AM   #1 (permalink)
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How my C/F triggers are made

I have had a small complaint above a trigger I made for a customer and would like to explain the process involved in making the triggers.
The sheet I buy is only within +- 0.015" so it can be under size one end and over size somewhere else, most of the time it is a better tolerance but this is the maximum it can be. When it is on the bigger side I have to machine it down to within tolerance for the marker it is to be installed in, and the more top line markers the tolerance is small, so usually if the sheet is more than 0.005" oversize this has to be done.
Any marks/lines on the back of the trigger are left by the cutter which is a solid carbide fish tail up cut router and it leaves small lines from the shape of the cutter also that is the 42 laminations of carbon fibre material .
All the holes are drilled with solid carbide drills as well as carbon fibre is a very abrasive materials, normal cutters (HSS) do not last very long and you start to get furry edges where the cutter goes through the material.
The carbide tools have increase the tool life from 5 triggers per cutter/drill to up around the 20+ mark which is OK but not fantastic, also the tolerance is a lot better.
The sheet is put into my small cnc router and set up for cutting using Carbide up cut fish tail router bits.
Once the trigger blanks have been cut the have to have all the edges de-burred to remove any furry edge or rough edges then the holding tabs are cut and the trigger is ready for having the trigger face radiused, which is done with a concaved grinding wheel with a 1/8 radius to round the face off, this is set up in a router and is free handed cut that is why each trigger slightly different as it all depends on the flow of the cutting with my hands.
Once this has been done it is time for the drilling and tapping of the threads for the adjustment screws, this is done in my small MILL/DRILL/LATHE as it drills nice and square, all the different markers have there own drill jigs, the radiused blank is put in the jig and vice and drilled then tapped, if any magnets are to be used in the trigger itself they are drilled with a carbide slot drill at the same time.
Once all the holes have been drilled and tapped it is time to make the nylon tipped grub screws so it is reset the MILL back to the LATHE put the tool post back on and drill the grub screws for the nylon, also the magnet screws are done next and they are drilled to take the magnets.
Then it is assembly time, that is put the nylon and magnets in the screws,
these are both pressed in not glued so they should never come out unless pulled/pushed or forced. The bearings then get pushed in with a dab of glue just to make sure they don't come out, due to the size of these bearings too tight a hole will cause the races to compress and give a lumpy feel to them or seize the bearings completely, this is one of the main reasons for using CARBIDE CUTTERS AND DRILLS.
Finally if any pins have to be made for the triggers they are done last as they are all made to a nice push fit as if it also is too tight it will cause the lumpy feel to the trigger pull or seize the bearings completely.
The very final thing to do then is get the envelopes ready for shipping which involves laminating them so they can stand up to the harsh handling by the postal services of the world, I have been doing this from the very start as the very first trigger I made got lost due to an envelope getting torn and the trigger falling out in the sorting office somewhere in Hawaii. The triggers are then packed and taken to the post office for shipping and off to you all the customer.
Hopefully this has not been too boring and has given you an insight into why these hand made triggers cost $65 usd including shipping.
I will post pictures tomorrow as I will be doing some triggers then.

John

picture of the carbide router cutter
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File Type: jpg up cut router.jpg (31.1 KB, 228 views)
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Last edited by acidcustom; 04-12-2013 at 03:49 AM.
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Old 04-12-2013, 03:47 AM   #2 (permalink)
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reserved for pictures
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Old 04-12-2013, 03:48 AM   #3 (permalink)
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reserved for more pictures
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Old 04-15-2013, 10:27 PM   #4 (permalink)
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Very cool. Looking forward to more pics. Cheers.
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Old 04-16-2013, 03:02 AM   #5 (permalink)
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You left out the part about carbon fiber producing a very nasty dust when it's machined, requiring use of a respirator. Which is really fun to wear for 5 minutes making Darth Vader quotes but not so fun to wear for hours while running a machine.
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Old 04-16-2013, 04:11 AM   #6 (permalink)
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Quote:
Originally Posted by PistolRogue View Post
You left out the part about carbon fiber producing a very nasty dust when it's machined, requiring use of a respirator. Which is really fun to wear for 5 minutes making Darth Vader quotes but not so fun to wear for hours while running a machine.
I only need a respirator is when cutting them out of the sheet and putting the radius on the front face as I use flood coolant when cutting them the rest of the time.
The other bad thing is the itching when grinding as trying to use gloves is not very manageable just have to use hand cream to get the fibres out of the skin after a shower
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C/F TRIGGERS AVAILABLE NOW
http://smg.photobucket.com/albums/v471/acidcustom/
check out the link for parts available now
http://smg.photobucket.com/albums/v471/acidcustom/
acidcustom@yahoo.com.au
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