A fellow ham radio operator Dennis (KI4DW) was in need of replacement weights for his Brown Brothers “bug” keyer. The weights are the easy part. I thought he needed the thumb screws duplicated too. Turns out he has the screws.
The weights I turned from a 3/4 in leaded steel bar on the PD400. The slots are cut with a 3/32 end mill on the X3. The digital readout was a real big help in free handing the slots. (CNC automation spoils me.) In the picture, the slots still need a bit of internal filing to square the inside corners.
The 8-32 thumb screws would be a lot more work to make exact copies. I was afraid of the time (and cost) I would spend on two of them. I have since discovered a good source for these at McMaster-Carr.
If I make any more weights, about a half hour in BobCAD should make the slot cutting easy work starting from dead center. Heck, the G-code would be easy to write from scratch.
Just a few hours work on developing these parts. CNCing the slot would make it much faster to produce more.