2020-04-06 (M) Electro Knife for Simulated Combat EleKSCo

The new adapters were all done printing, so I installed switches and held them against the pipe to line up everything. I drilled a couple of 3/32" (2.5mm) holes where the bolts would sit and fastened the adapter in place. Only the forward fastener got a nut since I could not reach the rear one which tightened like a screw into the pipe.
Nut inside a tube

The rear hole was small enough that the screw could tighten securely. Since most of the stress on this adapter will push it right into the pipe, it may be fine without a bolt. If this fails, I may need to print some a tool to hold a nut in place long enough to tighten it, since an ordinary wrench cannot reach.
Three assembled switch adapters

At the front of each handle, I pushed a trimmed rubber knife blade, then drilled two 1/8" (3.175mm) holes through the pipe and blade. I didn't use a drill press or careful measurements, so each blade and handle will be paired instead of interchangeable. After the first holes, I removed the rubber and bored out the holes to 1/4" (6.5mm), so I could push a couple of metal standoffs inside.
Installed spacers and corresponding drill bits

The spacers provided a socket for two pairs of #6-32 machine screws, one pair in the top, and one pair in the bottom. I tightened them until they sat flush with the plastic without distorting it excessively.
Adding countersunk bolts

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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