2023-07-22 (Sa) KeyRyptex Unusable rods and working electronics

The fiasco of the rods continued. I thought I ordered fully threaded rods, but when they arrived a day late, only the tips had threads, which was 100% my fault. The metal was stainless steel, but I wanted to trim and thread them. I cut three segments and kept the stock threads intact. I threaded the cut ends with an M3-0.5 die, but the rod did not stay perfectly seated. When I tried adding M3 nuts from my stock, I discovered the rod was too small. The rod was the same diameter as the ID of a nut, so the threads would not catch. I should have read the rod's description more closely.

I tried cutting 4-40 threads on the rod, but it was too large for the cutter die. I visited three hardware stores looking for threaded rod segments. I plotted which parts I would need depending on if I found M3 rods or 4-40, but I could not find either type. I gave up and ordered FULLY threaded rods with quick delivery.
Shallow threads

I wanted to determine why my battery charger/voltage booster board was not working. My first guess was a spoiled battery, and my second guess was a power-saving circuit built into the charging module. I poked around to confirm the voltage on the board, but I discovered it had an unreliable connection to the battery. I determined it was the switch and disassembled it to see if I could figure out the problem. The issue was when I soldered the wires, and the terminals pulled out far enough that they would not sustain a connection. I swapped out the switch, and the electronics worked reliably.
Switch innards

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
Completed projects from year 7
Completed projects from year 8

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