Reply by DylanC

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Posted on Cap Iron for Millers Falls 85 (Will One From A Stanley 78 Work?)

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206 posts in 3275 days

#1 posted 09-15-2016 11:24 PM

I decided to make one at work using a scrap of stainless steel. Simplified steps are listed below:

1. Trace the outline of the original onto the stainless.
2. Drill three holes: one for the retaining screw, one for the tension screw, and another to shape the radius where the cap widens to the width of the iron.
3. Remove everything outside of the outline with the horizontal bandsaw and grinder. Grind the bevel at the end of the cap so shavings don’t get jammed in the mouth. Shape to taste.
4. Tap the hole for the tension screw. Turned out to be a 1/4”-20.

When I did a test fit tonight I found I still need to take a bit off the width where the cap meets the iron, but that is easy enough to do. The only other loose end is whether or not to drill another hole and finish the “keyhole” for the retaining screw. The jury is still out on if I will do that or not.

-- Dylan C ...Seems like all ever I make is sawdust...

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