Please remember, this is just how I make my jump cups, others may do things differently.
These are the items you will need to make your jump cup.
1. Some sort of fine marker pen.
3. Small File.
4. Dowling you intend to use for your jump poles.
5. Wood you are using for your wings which will be drilled for the cups.
6. Long nose pliers.
7. Piece of good quality card.
8. Some thin metal (I'm using thin coated aluminium).
9. Scissors (+ Tin snips if needed to cut the metal).
10. Metal ruler.
First we are going to make a template which you will be able to keep using. Measure around your wood for your wings. Note these down, mine were 10x11x10 mms.
Next your going to make a 3 square grid on your piece of card from your measurements, these will be the side, middle and opposite side of the jump cup. For the middle square I like to add an extra 1mm to give the freedom to move once adding it to the finished wing.
Just a little tip - I personally like to use the edge of my ruler to get the angles right by lining up the longest edge.
Your grid should look like this.
Next add another lower section slightly longer than the middle box boundary outline, this will be the part which holds your poles. I have made mine 4mm wide but you might want to increase it.
Next carefully cut your template out with your scissors. This is your template complete!
Now take your piece of metal and the fine marker pen, place the template on top of the metal and trace around it with the pen.
Remeasure your grid and apply it to the metal version.
Please note - this next part needs to be handled with care as the metal is sharp!
Now your ready to cut your cup out, I personally like to use an old, strong pair of scissors as I get a more controlled cut but you can also use tin snips.
Next your going to measure your added strip and find the centre point, draw a line to mark this then add 1.5mm to each side of the line and mark these points with clearly visible dots. Your now going to cut into the strip on each side of these points leaving the middle bit still attached....do NOT cut the strip clean off. Hopefully you can see in the picture above (its turned over so you can see the cuts).
Find your dowelling pole and place this in the centre of the cup strip, now bend the strip around the pole. You will probably need your long nose pliers to help bend it right around at the ends. I now take the pole out and trim the ends so that the cup is more shallow.
Now take your pliers again and line the nose up with the lines that need to be bent, always go on the outer side of the middle square as shown above. Repeat for the other side.
Gently press the cup for the pole up until it touches the centre square. Remember not to keep moving this section as it can weaken and snap.
Take your small file and round off all the sharp edges. Once complete I clean up my cups with a cotton bud (Q tip) dipped in nail varnish remover to take off the marker pen as my paint primer hates it and it always shows though if left.
Check the new cup fits your wood (bend if necessary) and Congratulations! One jump cup.
I like to make up and drill my wing before adding holes to my cups. when going to add holes to the cups I hold it in place on the wing and mark it where the hole is then measure down and drill. A spare piece of wing wood is great to use to drill into as it sits perfectly in place and doesn't damage the pole cup.
When I have done everything above I prefer to spray my cups with a metal primer, normally a car primer followed by a car gloss spray. This just gives a smooth even finish.
As you can see I added a small tab to the side of my cup so I could add a chain for the pins, this is purely personal preference and it just stops me losing the pins, lol. The pins can be made from Looped Head Pins which normally come in silver or brass and are widely avalable, just check their thickness and strength as you don't want them weak.
I hope you have found this tutorial helpful and I also hope I haven't made it too complicated?
Have Fun!! :)