especially for any one following this page here is the completed project.
Some Photographs of the main frame of the Enigma Machine ( Repro Model )
Constructing the Rotors.
Making the finger notch disc.
Transporting case for the Enigma Machine.
Here is the new realigned keyboard arrangement, the temporary sleeved have been removed
Constructing my Enigma Keys.
Start by making the Alphabetical key inserts, i could not find any ready made Font so i got the letters made up on a C.A.D. system, this enabled me to get the correct diameter of the letters to insert in to the Keys and to " tweek " the overall look of the letter inserts, When the letters are correct the sheet is printed of, and embossed in a light plastic Laminating pouch, This will give the letters a hard plastic coating to protect them from wear.
It was difficult to cut out individual letters neatly with a scissors so i made a punch from a spare piece of aluminium bar ( the same bar that i made the key tops from ) this punch was machined on a small lathe to give a high sharp rim which will be used to punch out the letters through the laminated pouch.
Finished machined punch.
The letters to be punched out are fixed to a piece of chipboard with a dab of vaseline to keep the printed letters in place against the chipboard, this temporary jig is held in place in a bench vice with a piece of aluminium plate.
The tip of the punch is now held in place over the letter to be punched out, the outer concentric circle on the print out helps to center the punch at the right location for the punch out, when the punch is centered properly the vice jaws are slowly closed the punch tip will now slowly cut through the laminate material to punch out a perfect circular insert.
Rear view of laminated paper after punch have perforated the laminated sheet.
Punched out inserts.
Key top being machined on lathe.
Some key tops at various stages of construction.
Each Key top will have to be cut to a consistent thickness of 4.40 mm, this is a " Jig " i made from a hack saw blade some small bolts and a piece of metal which is 4.40 mm thick.
The three parts required to make the key, the keys tops are made from 15 mm bar and the spindle is made from 6mm tube.
Assembled key is held in a vice and a small amount of adhesive is applied with a small paint brush to the center of the key.
The individual inserts are now fitted to the tops of the keys to complete the assembly.
Set of completed keys.
Constructing the " Stecker " ( Plug ) Cable.
These plugs are non functioning and are for cosmetic purposes only, fixed to the front of the machine, to hold the plugs in position in the connectors i have inserted pieces of Brazing rod in to the plugs.
Assembling the " Steckerbrett " ( plugboard ).