2020-03-14 (Sa) Electro Knife for Simulated Combat EleKSCo

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.
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

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