How to: attach a piano wire to a ball bearing

[Soundguy]

Unfortunately, since the internet is so vast and easily harvested, my idea for a potential commercial product would not be private very long. My apologies for needing to be somewhat vague. I won't become a multi-millionaire but there is a small potential market I've identified.



I hadn't considered it being a 'lawnmower' type throttle cable, I was thinking more on the lines of a bicycle brake or motorcycle throttle made of stranded stainless cable, but the concept holds water!

I can actually make a small batch mold to cast lead onto a wire pretty easily, so again this is quite viable and a route I'd really not considered, so thanks to those contributing thus far, it's been quite helpful.

something that actually comes to mind is a cavity press that is a clamshell of 2 chunks of aluminum with a small channel for the wire terminating to a small cavity where I place a fishing split shot and pinch it down in my 12Ton press, it's worth an experiment.

That's the swage setup I had mentioned earlier. and you could put a small eye in the rod that sets in the middle of the lead ball, to help hold it in. If you went the cast route, you can harden lead with tin, and arsenic and antimony. You could also move up to something like zinc.

 

[medic0648]

If you are looking for a threaded steel ball with an approximate 1/16" wire have you looked at the balls for tongue and belly "rings" or "barbells"? Available in many sizes and gauges. Should be able to locate a supplier for just the balls.

 

[sd455dan]

Here's a challenge I'm faced with: How can I attach a 1/16" piano wire to a 3/16" to 1/4" ball bearing?

or.........

create a ball on the end of a piece of stiff wire? (I was thinking can a tungsten be 'balled' to that large of a size?)

I'm open to alternatives, so..

The base requirements are:

3/16" to 1/4" size ball of steel or aluminum attached to a short (1/2" to 3/4") 1/16" diameter metal shaft, like piano wire but could be any material that is stiff, like even tungsten.

I know this is NOT tractor related, but some of the best creative welding minds hang out here, as well as some very creative fabricators, so thanks in advance.

Since a non flexible tungsten is acceptable,- How about a stud gun used to pull dents out of car bodies?

Using the standard dent puller pin Should be a way of grounding the steel ball... It may be possible to (spot) weld the pin to the ball.

 

[frugalangler]

Since a non flexible tungsten is acceptable,- How about a stud gun used to pull dents out of car bodies?

Using the standard dent puller pin Should be a way of grounding the steel ball... It may be possible to (spot) weld the pin to the ball.

Now that's an great idea I will explore, I believe a clamp is easy to make, but my hard part was the welder part and a dent puller gun may just work!!!

Also, a good friend who's been welding for years recommended getting out my Henrob and using a micro-tip to heat a small puddle on the ball and then dipping the wire in and holding til it's cool, but since I've yet to light up the Henrob (I bought it because I saw one for next to nothing one day and he's been raving about it) I'm a little skeptical of my skill there, maybe a good reason to learn it.

 

[Ken M]

Construction Balls or Tooling Balls used by machinists. Many sources on the web.

ref: .250 dia ball with .125 dia shank

Carr-Lane CL-0-CB

Precision tooling ball used as a reference point for critical inspection, layout, and machining operations. Adjustable type has no shoulder, so it can be set at any desired height then locked with a setscrew. Concentricity between ball and shank is .0002" TIR. These Construction Balls are available with 1/4, 3/8, and 1/2" ball sizes. The 1/4" ball size is shown here. Made in USA.

Construction Balls – Adjustable Type (1/4" Ball) | Carr Lane

 

[SpringHollow]

Was there a reason these would not work? https://www.grainger.com/product/LOOS-Single-Shank-Ball-16X624?s_pp=false&picUrl=//static.grainger.com/rp/s/is/image/Grainger/16X623_AS01?$smthumb$

They would take just a few seconds to do.

Ken

 

[frugalangler]

Was there a reason these would not work? https://www.grainger.com/product/LOOS-Single-Shank-Ball-16X624?s_pp=false&picUrl=//static.grainger.com/rp/s/is/image/Grainger/16X623_AS01?$smthumb$

They would take just a few seconds to do.

Ken

thanks for the idea, but...
Unfortunately the 'shank' would interfere with part of the other parts of the device, if it had just a ball without the shank it would work. But, then it would be a simple drilled ball. I suppose I could cut the shank off, but I believe there are other options.

 

[sd455dan]

Now that's an great idea I will explore, I believe a clamp is easy to make, but my hard part was the welder part and a dent puller gun may just work!!!

Also, a good friend who's been welding for years recommended getting out my Henrob and using a micro-tip to heat a small puddle on the ball and then dipping the wire in and holding til it's cool, but since I've yet to light up the Henrob (I bought it because I saw one for next to nothing one day and he's been raving about it) I'm a little skeptical of my skill there, maybe a good reason to learn it.

I thought about that, (the clamp that is)

and It may be possible to use a nut to set the ball into and than connect a wire (for ground) between the stud guns outer ring to the nut . Then apply pressure on stud to ball and hit the weld button.

I have a stud gun but not sure I have any loose bearings that size.

Will be out in my shop today and if I find a ball in the size range you posted will give it a try and post the results.


ps a couple of concerns : stud gun comes with 2 different size pins and I can't remember their diameter -may be bigger than 1/16.

second the studs are made with a small flat on the bottom to reduce burn through of auto-body sheet metal but it should be easy to cut the small flat off the bottom.

 

[frugalangler]

I thought about that, (the clamp that is)

and It may be possible to use a nut to set the ball into and than connect a wire (for ground) between the stud guns outer ring to the nut . Then apply pressure on stud to ball and hit the weld button.

I have a stud gun but not sure I have any loose bearings that size.

Will be out in my shop today and if I find a ball in the size range you posted will give it a try and post the results.

That would be awesome, thanks. I don't have a stud gun but could get access to one if that proves out, I'd just have to barter a few favors ...... again!

 

[sd455dan]

That would be awesome, thanks. I don't have a stud gun but could get access to one if that proves out, I'd just have to barter a few favors ...... again!

Well I tried to use the stud gun... and with the size of bearings and not wanting a flat or shank on the pin it was a total failure. Some other method may work for you