My customer made a custom door, which was considerably thicker than a standard door. This meant that standard door knob hardware would be too short to reach through the door. Door knob extension kits are available, but these were also too short. To solve the problem my customer purchased a second door knob assembly so that he could scavenge the two shaft parts that were required. The task was to weld an extension to the outer piece that looked like half of a pipe. The inner piece appeared to be made of pot metal and I was reluctant to attempt to weld it. I know that Muggy Weld makes a Super Alloy 1 product that can weld pot metal, but a kit costs $105. My customer and I decided to machine a sleeve to extend the shaft, which would be glued on using Loctite 680. The first picture shows the drawing and the parts that my customer provided.
I was concerned that the sleeve would interfere with the numbs on the ID of the shaft so I ground them off.
I like to remove the plating before I machine plated metal to avoid smearing the plating on the area to be welded, because the plating will cause porosity in the welds.

The first machining task was to remove the radius on the end of the shaft in preparation for welding.
1. Drawing and parts
I was concerned that the sleeve would interfere with the numbs on the ID of the shaft so I ground them off.
2. Grinding off nubs
I like to remove the plating before I machine plated metal to avoid smearing the plating on the area to be welded, because the plating will cause porosity in the welds.
3. Etch off plating in HCL
4. Plating removed
The first machining task was to remove the radius on the end of the shaft in preparation for welding.
5. Squaring off one end
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