Project to organize/maximize my safe

I bought my safe at age 22 or so, owning a couple of handguns and ~5 long arms. I bought big, sure that I'd never be able to fill it, so I dedicated ~1/3 of the safe to shelf space. Fact forward 25 years and here I am with more guns than safe. I ran across these organizers on Amazon but wasn't convinced the juice was worth the squeeze. They look both expensive (for what it is) and pretty bendy. Then I ran across this tutorial for a much-improved DIY version.

I purchased all of the supplies, but I can't drill out the washers as shown in the instructions--they just won't dish out in the "countersunk" manner shown in the instructions--and you need to get them flush with the washer so the adhesive/velcro will stick. I was trying to do it with a drill and vise (as shown) and it was not even close... So I broke down and bought a portable drill press from Harbor Freight, confident that would do the trick. No joy. Still nothing but ruined drill bits.

So, it's true that I'm not Mr. Handyman, but I'm also not completely useless, and this project seemed well within my abilities. Any suggestions? What am i doing wrong?

Edited to say: Not sure why the links aren't working. Here they are again, and if needed you can cut/paste:

1st link: https://www.amazon.com/stores/GunSto...6-49FDD686DA42

2nd link: https://www.instructables.com/Gun-Safe-Firearm-Support-System/

The link didn’t post.

I know a guy that uses those things. It?s a pain getting things in and out but he definitely has a bunch of long guns packed in his safe.

I have more money than free time so I would just buy them rather than make them.

So you need to bevel a hole in a washer?

Buy a dremel. Grind the inside edge at an angle and the way around.

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Originally Posted by dogcaller

I bought my safe at age 22 or so, owning a couple of handguns and ~5 long arms. I bought big, sure that I'd never be able to fill it, so I dedicated ~1/3 of the safe to shelf space. Fact forward 25 years and here I am with more guns than safe. I ran across these organizers on Amazon but wasn't convinced the juice was worth the squeeze. They look both expensive (for what it is) and pretty bendy. Then I ran across this tutorial for a much-improved DIY version.

I purchased all of the supplies, but I can't drill out the washers as shown in the instructions--they just won't dish out in the "countersunk" manner shown in the instructions--and you need to get them flush with the washer so the adhesive/velcro will stick. I was trying to do it with a drill and vise (as shown) and it was not even close... So I broke down and bought a portable drill press from Harbor Freight, confident that would do the trick. No joy. Still nothing but ruined drill bits.

So, it's true that I'm not Mr. Handyman, but I'm also not completely useless, and this project seemed well within my abilities. Any suggestions? What am i doing wrong?

Edited to say: Not sure why the links aren't working. Here they are again, and if needed you can cut/paste:

1st link: https://www.amazon.com/stores/GunSto...6-49FDD686DA42

2nd link: https://www.instructables.com/Gun-Safe-Firearm-Support-System/

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They do offer countersunk washers, at most hardware stores. W/out reading the tutorial i "think" what you might want to use are these finishing washers.
https://www.globalindustrial.com/p/f...a6047b74060bb1




If not, Wulf's suggestion is the way to go. Or go to the hardware store and browse

I would also peruse McMaster-Carr for parts that might work. They have an amazing selection of random hardware.

can't help on the DIY version, but I'm very happy using the commercial product. My smallish safe was set up with 1/2 the width for rifles, and 1/2 the width for shelves. I ended up removing the shelves so I have rifles on both sides, and use the rifle rods.

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Originally Posted by ray1970

I know a guy that uses those things. It?s a pain getting things in and out but he definitely has a bunch of long guns packed in his safe.

I have more money than free time so I would just buy them rather than make them.

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I understand that. I'm in the same spot, but I kind of like having a project to work on--especially if I think it'll be an improvement on the original.

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Originally Posted by Osmosis

I would also peruse McMaster-Carr for parts that might work. They have an amazing selection of random hardware.

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I appreciate that. I checked there and they seem to have beveled washers that would do the trick, but there are large enough. I want 1.5-2" OD so there's enough room to have a good velcro patch.

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Originally Posted by Great-Kazoo

They do offer countersunk washers, at most hardware stores. W/out reading the tutorial i "think" what you might want to use are these finishing washers.
https://www.globalindustrial.com/p/f...a6047b74060bb1




If not, Wulf's suggestion is the way to go. Or go to the hardware store and browse

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Those would be perfect if they were just bigger (OD).

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Originally Posted by Wulf202

So you need to bevel a hole in a washer?

Buy a dremel. Grind the inside edge at an angle and the way around.

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I have a Dremel. What would you suggest grinding it with--is there a particular grinding bit you would suggest? It will be able to grind down a washer that a drill press with a drill bit couldn't cut? Is there such a thing as washers with softer steel? I need a ~2" OD washer with an ID of .25 - .30". I haven't been able to find a beveled washer with a large enough OD.

Maybe the real question is--Is there not a simple way to use a drill bit to bevel these out...?

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Originally Posted by dogcaller

I have a Dremel. What would you suggest grinding it with--is there a particular grinding bit you would suggest? It will be able to grind down a washer that a drill press with a drill bit couldn't cut? Is there such a thing as washers with softer steel? I need a ~2" OD washer with an ID of .25 - .30". I haven't been able to find a beveled washer with a large enough OD.

Maybe the real question is--Is there not a simple way to use a drill bit to bevel these out...?

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Not a simple or easy way to use drill bit to make a countersink in washer. Almost impossible to "hold" washer while being drilled by hand or on drill press.

I have made aluminium washers by drawing them on 1/8"(x whatever width you need to get washer size) thick material, use counter sink bit to make center hole and bevel, then use hole saw to cut out washer.

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Originally Posted by dogcaller

Those would be perfect if they were just bigger (OD).

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They are offered in other sizes. I have the stock velcro and rod setup. I used a staple gun and some spray adhesive, to secure the velcro mats to the underside of the shelf. No issues, so far.

You're way over thinking what should be a simple project. ..

Came across this website tonight. Might be useful as well. https://www.boltdepot.com/

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Originally Posted by dogcaller

Those would be perfect if they were just bigger (OD).

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They are made in bigger sizes.

The handgun hangers are made by other mfgs for less. Not really a high dollar concept.

Watching this thread to maximize my own safe needs.

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Originally Posted by Great-Kazoo

They are offered in other sizes. I have the stock velcro and rod setup. I used a staple gun and some spray adhesive, to secure the velcro mats to the underside of the shelf. No issues, so far.

You're way over thinking what should be a simple project. ..

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I've been accused of that before--with reason! The thing is, I now have all of the supplies for the DIY project, and I'd like to complete it. What is the approximate OD on the factory "tops" you have?

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Originally Posted by buffalobo

Not a simple or easy way to use drill bit to make a countersink in washer. Almost impossible to "hold" washer while being drilled by hand or on drill press.

I have made aluminum washers by drawing them on 1/8"(x whatever width you need to get washer size) thick material, use counter sink bit to make center hole and bevel, then use hole saw to cut out washer.

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Believe it or not, holding the washer isn't the problem. I have an attachment on my press that holds it perfectly still, but the drill bits barely make a dent, and I'm ruining drill bits. Also tried to use a countersink, which didn't work (not surprisingly, since they are intended for wood). I've drilled through much thicker metal with this press, which is why I'm flummoxed by the washers...

There are cone shaped grinder attachments for a dremel that might work. What is the approximate inside diameter you're working with? If it's large enough, those same grinder cones exist that are large enough to chuck into a drill. Or if you have a steady hand, you could just rim the inside with the smaller dremel version.

I just read through the tutorial and it looks like a great idea. I'm totally on board.

These are what I'm talking about.
https://lh3.googleusercontent.com/pw...-no?authuser=0

You could probably heat each washer until it is red hot and let it cool slowly so it looses it's hardening, but that might be extra labor intensive depending on how many you are doing. Also, if they are galvanized, might want to wear a respirator while you're grinding each one as you'll be heating up the zinc and making bad fumes.

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Originally Posted by dogcaller

I appreciate that. I checked there and they seem to have beveled washers that would do the trick, but there are large enough. I want 1.5-2" OD so there's enough room to have a good velcro patch.

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1.5 - 2 inches is a lot of velcro contact. Keep in mind every time you take something out of the safe you?ll be having to basically pull straight down to release the velcro and probably on several of them depending on what your going after and how much other stuff you have to move.

Personally, I?d be going for a 0.75 - 1 inch pad.

Also, as far as countersinking the washers, if you had access to a press you could use a ball bearing or maybe even one of the screws you plan on using and basically press your indent into the washers.

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Originally Posted by ray1970

1.5 - 2 inches is a lot of velcro contact. Keep in mind every time you take something out of the safe you?ll be having to basically pull straight down to release the velcro and probably on several of them depending on what your going after and how much other stuff you have to move.

Personally, I?d be going for a 0.75 - 1 inch pad.

Also, as far as countersinking the washers, if you had access to a press you could use a ball bearing or maybe even one of the screws you plan on using and basically press your indent into the washers.

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I appreciate that feedback. I will look into the 1" range. I don't have access to a press of that type.

Try this....

Place flathead large screw pointing up on a hard surface (steel plate if you have it).
Place 1" washer over screw.
Center short piece of 1" black pipe centered over washer.
Put on safety glasses and work gloves.
Take all your aggressions out by wailing on the top of the pipe with the biggest mallet you have.

Also 'Belleville Spring Lock Washers' might work: https://www.mcmaster.com/conical-was...-lock-washers/

That is a pretty good idea in lieu of a press.