Stuff happened... So didn't get to work on this much. Three days ago, I went to the garage to see if I could use my table saw to cut the 44 degree angles for the ramp blocks. As I was turning the angle adjust crank on the saw, it was getting harder and harder to do. Then heard a crack sound. The 30 year old plastic hand crank failed. The D section gave up and the hub cracked. Not going to get another plastic wheel.
![PXL_20211103_204157671.jpg PXL_20211103_204157671.jpg](https://www.hobby-machinist.com/data/attachments/341/341474-91386e1b2486f1e008b35ab099492870.jpg)
![PXL_20211103_204145195.jpg PXL_20211103_204145195.jpg](https://www.hobby-machinist.com/data/attachments/341/341475-e20a88eb9df1637dedee663cf81b6a27.jpg)
Looked around for some hand wheels and saw the cost was pretty high, higher than what I wanted to pay on a saw that I hadn't used in 15 years. Decided to make a handle out of scraps that I could find around the shop.
Design was a crank lever with a rotating handle. Hub was a piece of A36 1x1 stock cut to 1.125" long. Drill 1/2 diameter hole 5/8" deep. Drill through hole for a 10-32 screw, matching the D shaft. Put in a 1/4-20 set screw. Lever was a piece of rusty scrap 1/8" x 1", cut to 3.5" long. After the hub was complete, I welded the lever to the hub. Welds weren't pretty, but they are good enough. You are looking at version 2. Version 1 I did on my mini-lathe and had an unexpected flub up. Somehow the taper in the tailstock was not seated well enough and the drill wallowed around. Had a 0.560" hole. No good. Supposed to be 0.50" Did it over on the mill. Came out as I had expected.
![PXL_20211103_163323112.jpg PXL_20211103_163323112.jpg](https://www.hobby-machinist.com/data/attachments/341/341476-5a5193181a1839f151c32dc3b62e1762.jpg)
Used a piece of 1/2" rod 3.5" long and single point threaded one end to 3/8-16 for a length of 5/8". At the other end, it was drilled and tapped for 1/4-20. Then made a thick washer that was 3/4" OD, and 1/4" ID.
Finally cut a piece of 1/2" PVC pipe that was just smaller in length than the distance between the lever and the washer. I present to you - scrap box hand crank.
![PXL_20211103_163311125.jpg PXL_20211103_163311125.jpg](https://www.hobby-machinist.com/data/attachments/341/341477-570e398bc32c1f082e9d9e9bb32525d0.jpg)
The hand crank fit perfectly on the angle D-shaft. This fixed my saw. So I cut some wood. Cut the 44 degree (or close) pieces for the stairs. Also cut the wood for the trolley. Finally get to put somethings together tomorrow.
![PXL_20211103_213450466.NIGHT.jpg PXL_20211103_213450466.NIGHT.jpg](https://www.hobby-machinist.com/data/attachments/341/341478-671bbfbe194d4642b5cacc62d7e8d6ca.jpg)
Now have the eye-bolts and hopefully all the hardware to proceed. Definitely fall here. Temperature is only in the 50's during the day time. (10C)