Making a Deburring Tool from a Razor Handle

[Paul Jones]

I had an old Gillette Sensor Excel razor with a broken blade clip that couldn’t be repaired. I converted the handle part into a deburring tool handle. The razor handle has a great feel and provides an excellent way to deburr parts.

I advise wrapping the razor handle near the head-end with a few loops of copper wire and twisted close before sawing off the head-end. This prevents the thin stainless steel sheet metal on the handle wrapper from catching and bending when being cut.

Next, on the lathe, I made a new head-end part from stainless steel 303 rod for holding the E100 and S100 type deburring cutters from Shaviv. One end is drilled to fit the handle and the other end drilled and reamed 0.126” to fit the deburring cutter shank. The new stainless steel part has V-grooves spaced at 0.20” along the barrel. A 6-32 pointed end set screw captures the Shaviv deburring cutters while allowing free rotation. The new stainless steel part is 0.430” in diameter and drilled 0.358” (Letter T drill) by 0.63 deep. This part slides onto the razor handle and then held in place with Loctite 680 (or superglue slow setting gel).

[Hotz]

Great idea, nice job ...

[kbalch]

Thanks Paul! Very clever and the best use of a cartridge razor I've ever seen. Dedicated DE guy here…

I've added your Deburring Tool to our Metalworking category, as well as to your builder page: Paul Jones' Homemade Tools. Your receipt:

Deburring Tool by Paul Jones

tags: lathe, hand tools, deburring

[Paul Jones]

Thanks Ken. The moment I picked up the broken razor and felt its balance in my hand, I knew it deserved a second life ...

[rossbotics]

Kool idea Paul, I'll have to remember this one

[DIYer]

Wow, that extra step in knurling the handle shows your dedication! Me, I would have used the handle as is.

[Paul Jones]

Quick Update:

I made a minor modification to the razor handle deburring tool by using a small 1/16" dia. ball bearing at the bottom of the set screw hole for better trapping the E100 and S100 type deburring cutters from Shaviv.

This allows the vee-recess in the deburring cutters to move freely and easily rotate against the smooth surface of the ball bearing. The ball bearing is loosely trapped at the bottom of the side hole with a 6-32 cup-end set screw. I used the green wicking type 290 Locktite to hold the set screw in place but it can be easily removed for replacing the deburring cutters as needed.

Thanks for looking,
Paul Jones

[mklotz]

Well done, Paul.

Useful handles can be rescued from all sorts of things. Broken kitchen tools have yielded several for me. In the days when rubber stamps were still in wide use I collected the discards and fitted the handles with engraving burs and occasionally needle files.

Rather than sawing the head off and risk deforming the metal, perhaps a Dremel cutoff disk? I know from experience that when sectioning thin aluminum soda cans, that works better than scissors or box cutters.

[Toolmaker51]

While handy, the handle for replaceable deburr whips are too dang big for certain work, and never fit shirt pocket. This is far more useful. And reminds me of a post to contribute. Way behind on writing activities - been building what might be called an upright or open side sheetmetal brake.

[Paul Jones]

I have to admit the old Gillette Sensor Excel razor handle has the best feel and heft for doing accurate deburring operations. The problem is the vintage Gillette Sensor Excel razors from have become an expensive item at the online auction site we all love and use. I would like to find another one with a broken head and make a second deburring tool for using other styles of debur cutters.