2020-03-11 (W) Electro Knife for Simulated Combat EleKSCo

The printable paper template for the metal bars needed a few changes that I was able to calculate and measure from the last. The bars had to be longer, seven inches total, and I wanted to try one-inch wide aluminum bars.
New bar template

When I cut metal bars, I spend half of my time rounding the metal bars, and I still needed a guard, so I decided I would print guard to protect square ends. I had to extend the model so the metal corners wouldn't get to close to the edge. My old metal bars were 3/4" wide, and my spacers were the same so that I can make the entire handle from aluminum bars.
A solid bottom from bar stock

The handle was getting large, and I still couldn't fit all the components inside. I could probably shorten the handle, but the circumference, one-inch on two sides, and one-and-a-quarter-inches on the other face were difficult to hold.
A big handle

After I made an oversized handle, I overtightened and broke a bolt inside the handle. After that, I improperly trimmed a long bolt and got the scrap stuck inside the tool, so I spent an hour fishing that out. I was done for the day.
Broken screw
Impaired tool

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

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