Building Ronja Holder

Overall view

We are going to build a holder:

Postscript / PDF / EPS / BIG png / DXF (qcad)

Quoin template

If you have exact printer, print out these three templates and glue the appropriate one on your 100x100 steel section.

Expanded quoin templates

Postscript / PDF / EPS / BIG png / DXF (qcad)

Aiming Gauge

If you have accurate printer, print out this template, glue on a tin, and cut or chisel out.
If not, measure the gauge manually. The number indicate width of the part in millimeters.

Purpose of aiming gauge

It is for checking minimum, maximum and starting compression of the rubber aiming blocks.
Lead of the M8 screw is 1.25mm. The useful range is 6mm or 4.8 turns.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Drill out the quoin.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Plate template

If you have accurate printer, print out this template, otherwise jump to the next box ("Drill out the plate").
The template is for 4 identical plates, you need only one for a holder
The gap between the templates is suitable for a saw, too.
Cut out the template and glue on the 90x8(10,12) flat steel

Postscript / PDF / EPS / BIG png / DXF (qcad)

Drill out the plate.

Postscript / PDF / EPS / BIG png / DXF (qcad)

Blocks template

If you have accurate printer, print out this template, otherwise jump to the next box ("Drill out the plate").
The template is for 4 identical plate block and 4 identical cross blocks, you need only of each for a holder.
The gap between the templates is suitable for a saw.
Cut out the template and glue on the 25x25 square bar

Postscript / PDF / EPS / BIG png / DXF (qcad)

Drill out the cross and plate blocks.

Rubber block drilling

Drill 8.5mm hole in each rubber block excentrically, with center 10mm from the edge. Use 9.5mm or so drill bit.

Bang the blocks with a big hammer along the edges to bulge them out to cancel out possible convexity of the sides.

Grinding burrs

Grind the area around holes with emery paper flat so that there are no burrs (they could creep under the bolt preload with time).

Parts to be washed and painted

Quoin
Plate
Cross block
Plate block

Cleaning

Fill a bucket with hot water and add detergent, for dosage see the bottle label
Throw all pieces with templates into the bucket and let the templates soak off.
Use emery paper to remove noncohesive rust from pieces where templates weren't used.
Wash parts to be washed plus parts already in water in the bucket using a brush or sponge to get rid of all grease
Place everything wet on a rag and dry with hairdrier while turning around.
Now remove noncohesive rust from pieces where templates were used.

Critical zones

Critical zones for Plate are on the picture (from both sides). The remaining pieces have them:

plate block where plate will be attached (8.5mm holes)
plate block where cross block will be attached (10.5mm holes)
cross block where plate block will be attached (10.5mm holes)
cross block where console will be attached (10.5mm holes)
quoin where heel will be attached (6.5mm holes)
quoin from inner side around the four 8.5mm holes

Painting

Paint all parts to be painted according to Fundamentals of manufacturing operations with regard to critical zones previously defined. Top coat is white. The photos are showing red primer.

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Assembly

Assemble the holder. Mirroring is insignificant (the holder can be cofigured to accomodate particular situation). The 3D model shows intermediate stage of assembly, the photo final assembly.

Accessories

Keep the rubber blocks, 3 M8x50 bolts and 3 M8 jam nuts for future mounting.