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Plug-in rack end

An experiment in making a plugin style rack eyelet or "dropout" for a rack. I started with 3/8" 1018 and turned it down to have a 5/16" OD and an ID to fit inside 5/16" x 0.035 tubing. The final result didn't have enough metal around the eyelet, so I brazed it and then cut it off to check my work.

I'll try again keeping an OD of 3/8" at the eyelet portion. This will leave some more metal and make it stronger. The tricky part will be getting a smooth transition from 5/16" to 3/8".

I think the final look is a lot cleaner than my tab style rack ends, so I'll continue to explore this approach. It is also easier to braze (but significantly more work to make).
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After a little cleanup with emery cloth.  Just a fine line of brass at the transition from the plug to the tubing.  This would look very clean once painted or plated.
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After a little cleanup with emery cloth. Just a fine line of brass at the transition from the plug to the tubing. This would look very clean once painted or plated.

  • Untitled photo
  • Turning down the OD to 5/16" (from 3/8").
  • Turning down the part which fits inside the tubing
  • This is our blank.
  • Drilling the insert to remove some material and save a little weight.  It also makes the brazing a little easier (less metal to heat up).
  • Parting the blank off on the lathe.
  • The completed blank.
  • There is a nick here that I made with the edge of a half round file.  It will be used to start filing with a round file.
  • I've started filing one side.
  • Some filing on both sides.
  • More of less finished with the filing.  I can do some cleanup once it is brazed into the tubing.
  • Using the 4-jaw chuck to drill a hole for the bolt.
  • Fluxed up and ready to braze
  • Brazed.  I added a little too much brass, but we can clean that up.  I also got it a little too hot (some of the flux is burned).
  • After a little cleanup with emery cloth.  Just a fine line of brass at the transition from the plug to the tubing.  This would look very clean once painted or plated.
  • A bolt fits.  There isn't much meat though, and the eyelet bent pretty easily.  So I cut off the head.
  • Not a great photo, but I could see that there was brass all the way around on the inside.
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