Having bought a combination mill instead of a flat one would really
have solved your problem, but you have to work with what you’ve got.
Without a drawing machine, you are only going to be able to pull
fairly small diameter wire by hand unless you’re lifting those big
weights at the gym. It can be brutal without the draw machine. They
are not so expensive, though. My hand winch powered one (less than
$200), which works great, is mounted to an aluminum fold-up
sawhorse, so it stands in a corner when it’s not being used. I only
use it for round wire, though, as my true square, rectangular, and
half-round wire is all made on my Durston combination mill with an
assortment of custom-made side rollers (half round up to 11 mm wide).
The rolling mill will certainly be the fastest and easiest way to
reduce the diameter of your wire stock. If you are only able to use
the side roller extensions on your mill to make wire, then you will
be limited in the size of wire you can generate with your rolling
mill. Sure, you can get a machinist to make you any shaped rollers
that you can dream up (very neat!), but due to the roller’s size (
3/4 to 1 in wide, usually) You won’t get very many sizes of grooves.
Remember, you will have to get sets of grooved rollers made, a top
and a bottom, which should match. You could have 2 sets of rollers
made, smaller sizes, and larger sizes, as an example. My machinist
charged me $50 ea. for my rollers, so you’d be looking at over $200
to have 2 in. or less of wire-making grooves. Who knows what your
machinist would charge you for the custom rollers. Durston Co. has
grooved side rollers you can buy from their factory in London, but
they are not cheap, by any means.
Durston does have a satellite factory (for refurbishing Durston
mills) near Phoenix, run by Matthew Durston’s father, Will. What
about inquiring whether they could swap out your flat rollers for a
combination set? Worth a phone call. The Durstons are really nice
folks, each of them. Those triangular grooves you want have a
flattened corner at the bottom of the groove. It has many uses, but
the wire-making purpose is to relieve stress generated at the sharp
corner of the wire. Cracks form easiest on the sharp edges. No, I
don’t know of a how-to book on using the rolling mill, but we at
Whaley Studios are making plans to film a comprehensive DVD on the
rolling mill in the near future. It really is needed. We’ll let
everyone know when we get the DVD edited and ready to go.