"Airy R.Bean" wrote in message
...
Is there a "kink" for setting up a slitting saw to saw through
round bar stock along the axis, so that the slot is exactly
across a diameter? (I presume this to be a similar problem to
setting up accurately for cross-drilling)

This is actually a Ham Radio application; I wish to make
up some very large banana-type plugs from the 1/4" round
bar stock that I have in small quantities. For this, I will need
to saw two diameters in a cross shape, and then splay
out the leaves slightly to make a springy and rubbing contact.



I put the saw mandrel in a lathe chuck and made a block with a hole and
setscrew to mount on the cross-slide. Did this to slit the threaded end of a
bolt - it has a countersunk hole lengthways through it and when a smaller
screw is thightened it locks the threads. This bolt is the mount for a
ball-turning attachment; I wanted to be able to lock the mounting bolt at
the right clearance without having it cock or move sideways, so a locknut
and a setscrew were both out.

I had to thread the hole through my block, but you don't need that. If you
wanted to get fancy you could make a shouldered sleeve with your setscrew
holding the stock, drill a hole in the shoulder, and two holes in the block
for a pin to set your 90 degree cuts.

Thanks for your ideas - it's always the way that there's more
though and effort needed to be put in to make the jig than
to make the device in which you're interested!

"jtaylor" wrote in message
...
I had to thread the hole through my block, but you don't need that. If
you
wanted to get fancy you could make a shouldered sleeve with your setscrew
holding the stock, drill a hole in the shoulder, and two holes in the
block
for a pin to set your 90 degree cuts.

"Airy R.Bean" wrote in message
...
Thanks for your ideas - it's always the way that there's more
though and effort needed to be put in to make the jig than
to make the device in which you're interested!

"jtaylor" wrote in message
...
I had to thread the hole through my block, but you don't need that. If
you
wanted to get fancy you could make a shouldered sleeve with your
setscrew
holding the stock, drill a hole in the shoulder, and two holes in the
block
for a pin to set your 90 degree cuts.


If you're making more than half a dozen it'd be worth it.

I have to make up about 14 such plugs.

(Although a nagging voice inside suggests that I should
also consider the "Binding Post" approach together with
spade terminals)

"jtaylor" wrote in message
...
"Airy R.Bean" wrote in message
...
Thanks for your ideas - it's always the way that there's more
though and effort needed to be put in to make the jig than
to make the device in which you're interested!
"jtaylor" wrote in message
...
I had to thread the hole through my block, but you don't need that.
If
you
wanted to get fancy you could make a shouldered sleeve with your
setscrew
holding the stock, drill a hole in the shoulder, and two holes in the
block
for a pin to set your 90 degree cuts.

If you're making more than half a dozen it'd be worth it.