For this project, I wanted to create something that was functional and beautifully simple. The first idea was to create a 15mm hex wrench for use on bicycle rims (for when you get a flat tire and need to change out the tube). Upon calculating the tightening torque the tool would make with the given dimensions (approx. 95 lbs), I decided it was probably not the best idea to make this kind of tool. Another idea came to mind, a camping mirror that could be clipped to a backpack when not in use. The design would include two holes at the bottom so the user can fix it at any height for hands-free use and an additional slot at the bottom would accommodate a triangular stand for tabletop use or decoration purposes.

The first step was to edit the diamond file with Adobe Illustrator. The completed file was then transferred to the plasma cutter where I learned the importance of resetting the lab computers. On my first attempt, the plasma cutter finished the mirror section, but the computer froze when cutting the triangular stand. After re-starting, the program worked flawlessly. Cutting each piece took about 26 seconds and was very fun to watch.

Fishing out the cut pieces was quite disgusting and took a while. I kept finding leftovers of other projects in the brown slurry. After looking around for what seemed like ages, I found my work pieces. The final product did not have too much slag, which meant the dimensions were relatively close to the original drawing. The next step was to use the angle grinder for slag and burr removal.

After using the angle grinder, I wanted to make sure the slot for each piece was the right depth (in the drawing I deliberately made it smaller to keep the clearance low for a tight fit). I heard a faint cry from the machine shop, it was quite distinct, something I have heard before; the milling machine! I asked Joe for a few moments with one of these marvels of manufacturing, he gladly helped with the process and gave me a history lesson about how the United States fought the Spain for control of Puerto Rico, and how President McKinley was assassinated shortly after(I need to brush up on my history). Back to making diamond mirrors. The end mill we used was 1/8″ since we could not find a smaller one (not that it would matter, using a smaller bit on steel would have been a slow process with a high risk of breaking the cutting tool). Surprisingly, the slots were quite close to the desired length. The next step involved making sure the holes were circular and the appropriate diameter for which a table drill was the only solution.

The holes definitely gave it a camping-feel. I tested them using my own carabiner key ring.

Using the table drill created some additional burrs near the holes. I thought using a file instead of the angle grinder was a better idea, this could not have been more true. The file gives you much more control over the amount of material removed and creates lines in a single direction (this better for the sanding process).

After removing the burrs came the best part; sanding. I needed to go for a mirror finish, which requires at least 1,000 grit sanding at the final step and subsequent polishing. I wanted to use 2,000 paper but there was none available at the shop. I started using 220 grit on the first piece, this was a very poor decision on my part since the angle grinder cuts very deep grooves into the work piece (should have used the trusty old bastard(file)). I decided to clear the grooves with the 220 for the first work piece, but would use 120 for the second work piece. The grit order was 150, 220, 400, 1,000 which took about four(4) hours of non-stop sanding. No, I am not exaggerating…four hours in the OEDK…sanding. Remember when Dr. Wettergreen said that post-processing is sometimes twice as long as the material processing stage…for this particular case it was literally 600 times longer. Having spent so much time focused on sanding was very therapeutic. It was a means of relieving stress that had built up over quite some time. The results of the sanding definitely paid off. Everyone left at the OEDK at midnight was able to witness the completion of my sanding process, and saw themselves in my work (literally).

The magnetic vice reminded me why I love magnets so much…

There was some debate as to the use of clear coating on the finished diamonds. I was unsure if the mirror finish would be as noticeable so after polishing on the buffering wheel, I did not apply a clear coat but will do a test to see if the finish holds up. You may wonder why the backside of the diamonds were not even cleaned up using 120 grit. This is because I wanted to create a contrast between the original piece and the final product. This is a representation of patience and a reminder to never give up, as great things can be accomplished with enough work and dedication. Below, a riddle.

This thing all things devours;
Birds, beasts, trees, flowers;
Gnaws iron, bites steel;
Grinds hard stones to meal;
Slays king, ruins town,
And beats mountain down.

                                 -Gollum

What is the thing he is talking about?

The final step was to sand the triangle stands with 120 grit paper for spray painting. Nick was kind enough to lend me some of his shocking orange spray paint. The color is important to avoid losing them when out in the field. The final product has gotten some admiration and my best friend has asked for a copy.