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I was attracted to flared tubing because it's simple and unlike pins - has shear and tension strength. In my (not always) humble opinion, it is superior to straight tubing. So I tried my hand at tube flaring this morning with the dies from USA Knife Maker http://www.usaknifemaker.com/tube-flaring-dies-for-fastening-handles-p-2969.html

The dies are easy to use if you experiment with their formula for tube length and countersink diameter. I wanted the flare to be below the finished surface. The third try (upper right in last pic) was a charm using the following formula:

1. cut thin walled stainless tube and square off ends to equal material thickness

2. countersink 1/4" tube hole to .4 diameter

3. flare tubing











Yes, it's so simple a monkey (like me) can do it!

Have a great Independence Day!
 
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thats pretty neat. i never thought about this to fasten handles. something i might think about. flaring is easy, i do it alot for industrial and automotive applications.
 
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