All the work with clamping aluminum bar stock seemed silly when I remembered that hardware stores sold square aluminum tubing. The inside dimensions were 1/16" (1.5mm) more on each side.
12mm switches are meant for PCB mounting, and I needed to access it from inside a square tube. I designed a couple of parts that would fit inside the aluminum and hold the switch. The key was that they could fit inside the handle, but when I fastened them together with a bolt and nut, they would expand outward and seat themselves against the inside diameter and hold securely. Each side had to provide enough clearance to move it in place while holding the switch and its cap, so it had to expand quite a bit.
The back of the square tube needed something to keep the corners from scraping people's skin, so I sketched an idea for a couple of hemispheres that would fit inside the handle and accept a hexagonal spacer. I never modeled this because I forgot that a half-circle would not cover the corners unless it extended past the square on the flats.
GitHub repo for EleKSco.
The rest of the posts for this project have been arranged by date.
First time here?
Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6
Disclaimer for http://24hourengineer.blogspot.com and 24HourEngineer.com
This disclaimer must be intact and whole. This disclaimer must be included if a project is distributed.
All information in this blog, or linked by this blog, is not to be taken as advice or solicitation. Anyone attempting to replicate, in whole or in part, is responsible for the outcome and procedure. Any loss of functionality, money, property, or similar, is the responsibility of those involved in the replication.
All digital communication regarding the email address 24hourengineer@gmail.com becomes the intellectual property of Brian McEvoy. Any information contained within these messages may be distributed or retained at the discretion of Brian McEvoy. Any email sent to this address, or any email account owned by Brian McEvoy, cannot be used to claim property or assets.
Comments to the blog may be utilized or erased at the discretion of the owner. No one posting may claim property or assets based on their post.
This blog, including pictures and text, is copyright to Brian McEvoy.
2020-02-26
Square tubing and how it fits a battery holder
12mm switches are meant for PCB mounting, and I needed to access it from inside a square tube. I designed a couple of parts that would fit inside the aluminum and hold the switch. The key was that they could fit inside the handle, but when I fastened them together with a bolt and nut, they would expand outward and seat themselves against the inside diameter and hold securely. Each side had to provide enough clearance to move it in place while holding the switch and its cap, so it had to expand quite a bit.
Sketch for compression switch holder
The back of the square tube needed something to keep the corners from scraping people's skin, so I sketched an idea for a couple of hemispheres that would fit inside the handle and accept a hexagonal spacer. I never modeled this because I forgot that a half-circle would not cover the corners unless it extended past the square on the flats.
Sketch for a cap with some notes
GitHub repo for EleKSco.
The rest of the posts for this project have been arranged by date.
First time here?
Completed projects from year 1
Completed projects from year 2
Completed projects from year 3
Completed projects from year 4
Completed projects from year 5
Completed projects from year 6
Disclaimer for http://24hourengineer.blogspot.com and 24HourEngineer.com
This disclaimer must be intact and whole. This disclaimer must be included if a project is distributed.
All information in this blog, or linked by this blog, is not to be taken as advice or solicitation. Anyone attempting to replicate, in whole or in part, is responsible for the outcome and procedure. Any loss of functionality, money, property, or similar, is the responsibility of those involved in the replication.
All digital communication regarding the email address 24hourengineer@gmail.com becomes the intellectual property of Brian McEvoy. Any information contained within these messages may be distributed or retained at the discretion of Brian McEvoy. Any email sent to this address, or any email account owned by Brian McEvoy, cannot be used to claim property or assets.
Comments to the blog may be utilized or erased at the discretion of the owner. No one posting may claim property or assets based on their post.
This blog, including pictures and text, is copyright to Brian McEvoy.
2020-02-26
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