Shims#
The steel shims in the fly holders are ordered from Etchit (www.etchitmn.com, Randy Johnson, Sales Manager, randy@etchitmn.com, 763-450-3130). The most popular shape is the R92 shape (rounded_head_taper_back_92pct_v07 - R92).
These designs are currently on the wilson lab github page, and are inventor files.
Cone-shaped Holders#
The cone-shaped fly holders are ordered from Protolabs (www.protolabs.com). They provide both 3D printing and CNC machining depending on what you need.
- Service: CNC Machining
- File Format: STEP (.stp or .step)
- There is an option in Autodesk (.ipt) to export as a CAD format
- Material: acetal homopolymer delrin 150 (black), now listed as Acetal Homopolymer (POM-H) (black)
- This material is rigid and light, but does not absorb liquid
When requesting a quote, the manufacturer will likely indicate that the cone is too thin and there are edges that will not be machined properly. That is fine. Just order a handful more than you need (~5/order) with the assumption that some will turn out damaged.
Orders typically take <1 week after final submission.
These designs are currently on the wilson lab github page:
https://github.com/wilson-lab/design-files
Foil Cone Holders (Noah Edition) DRAFT#
This is an instruction manual on how to make Noah’s custom designed foil holders. Some people have found that having more of the eye exposed leads to more menotaxis.
Select type of foil:
R best, S second, m too small (may work for males)
The foils are etched from 302 full hard temper stainless steel shim stock, 0.001", by Etchit (www.etchitmn.com, Randy Johnson, Sales Manager, randy@etchitmn.com, 763-450-3130).
Prep foil for folding: Do this in gloves
Cut foil out of large sheet. Trim the sides, front, and back for easier loading into holder. These cuts do not need to be precise.
Shape Foil
Under microscope, place the foil on 20 degree cone (3D printed in house) Align the center of the fly hole to the apex of the cone and tape the front edge of the foil flush with the cone. Wrap the foil around the cone so that the back edges nearly touch and the apex of the cone is still centered in the fly hole. Where the two edges meet in the back, keep a very slight gap in the back to make sure hole large enough for your flies (this can be adjusted to personal preference, with a larger gap resulting in a looser fit).
Make sure apex of cone is centered in hole Starting at the base of the foil cone, add bits of tape spanning the foil seam / gap. Progressively add tap higher and higher up the foil until you get within a couple mm of the hole. Now working back from the top of the foil cone towards the base, add UV glue onto the seam, curing and removing tape as you work your way down. Work in small sections so glue covers foil seam, rougly 5 sections Use forceps to get foil off cone Cure other side of foil seam.
Attach to metal frame holder
Snap the tab off the back of holder off and sand down sharp edges Snap foil into holder (4 notches)
Align back top of foil with top of metal holder surface
Align front top of foil to bottom of metal holder Put into large acrylic holder Use forceps to make minor adjustments to foil positioning
Use UV glue to tack the foil to the holder
Epoxy the edges apply with broken cotton swab (Be liberal with it) Around the bottom underside, fill the top, and running down the seam
leave about 1/3 of the seam closes to the fly as just UV glue (no epoxy)
Final Steps
Allow epoxy to cure
Label holder with paint marker