When I was still picking out handle material, I bought a foot (300mm) of polycarbonate, aka Lexan, pipe. One reason I picked it was that the online measurements were precise, and I knew it would be durable. In the end, I built a single handle with this material because I didn't want to burden everyone else with the cost if I could find a cheaper alternative.
I haven't done a lot with improving the blade design since my other teammates were eager to tackle that issue. I suspect they wanted to jump on the part that tossed sparks, and I don't blame them. In the meantime, my solution was aluminum tape over the rubber blade, and the more I used it, the more I liked the idea. Since it might not last a long time in a knife fight, I figured the best course would be to have spare strips of aluminum on hand, so I drafted a CAD file with templates for the two types of rubber knives I had on hand.
I had enough experience and usable parts, so I started building a final run. I planned to construct three identical knives to make sure all my pieces fit together. If that worked out, I would buy the fourth set of components, and go through a final build with pictures so I could make concise instructions. I was waiting for parts, so I detoured for a few days.
Even though the aluminum tape was working out, I still wanted to experiment with different materials, like "conductive rubber" and Velostat. The rubber was actually a silicone sheet with embedded carbon fibers, and it was expensive. I already had some Velostat on hand, and more places online sold it. I tested rubber cement and E6000 on both materials, but only E6000 and Velostat stuck.
By this point, I had a knife blade with an old hole pattern, so I tried a full-scale piece of Velostat even though I knew it might destroy it. When I applied E600 to the plastic, it curled up. While the glue cured, I kept it pressed, but the wrinkles persisted. Even though the plastic and rubber stuck together, it was ugly.
One night, I was feeling squirrely, so I wrote a silly article based on the exhibition fight rules the team agreed upon. Here is a link to the PDF with the script.
The rest of the summary posts 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 on 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.
Clear handled prototype
I haven't done a lot with improving the blade design since my other teammates were eager to tackle that issue. I suspect they wanted to jump on the part that tossed sparks, and I don't blame them. In the meantime, my solution was aluminum tape over the rubber blade, and the more I used it, the more I liked the idea. Since it might not last a long time in a knife fight, I figured the best course would be to have spare strips of aluminum on hand, so I drafted a CAD file with templates for the two types of rubber knives I had on hand.
Screenshot of blade shape templates
I had enough experience and usable parts, so I started building a final run. I planned to construct three identical knives to make sure all my pieces fit together. If that worked out, I would buy the fourth set of components, and go through a final build with pictures so I could make concise instructions. I was waiting for parts, so I detoured for a few days.
Semi-flexible water pipe with a blade shoved into the end
Even though the aluminum tape was working out, I still wanted to experiment with different materials, like "conductive rubber" and Velostat. The rubber was actually a silicone sheet with embedded carbon fibers, and it was expensive. I already had some Velostat on hand, and more places online sold it. I tested rubber cement and E6000 on both materials, but only E6000 and Velostat stuck.
Adhesive test
By this point, I had a knife blade with an old hole pattern, so I tried a full-scale piece of Velostat even though I knew it might destroy it. When I applied E600 to the plastic, it curled up. While the glue cured, I kept it pressed, but the wrinkles persisted. Even though the plastic and rubber stuck together, it was ugly.
Wrinkled Velostat on a knife blade
One night, I was feeling squirrely, so I wrote a silly article based on the exhibition fight rules the team agreed upon. Here is a link to the PDF with the script.
The rest of the summary posts 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 on 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.
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