2026-09-04 (F) Weekly Summary

I asked a coworker for help making a more secure cap, and he suggested I make a bolt with a chamfered tip, which should work well. I tried stacking a ball bearing on top of a stock bolt, but the ball got stuck. I started looking at the external switch apparatus and enlarged it, but I still need to change some variables.

Yeah, I know what it looks like

I deepened the external switch holster to fit the switch and added an inner lip to accommodate the button cap’s ridge. After printing both halves, I realized they did not fit but once I corrected it, the new cover pieces fit perfectly. For the final touch, I added a layer of nitrile from a disposable exam glove, which turned out to press the button when overstretched. After trimming the material, I was pleased to have a functional, covered switch.

Pushbuttons with nitrile liners

I started my wiring project with the 18650 and 18350 battery holders, but ran into issues because the positive terminal was too narrow for the wiring. To fix this, I plan to add a few millimeters to the front of the holder for a better fit.

The wiring sticks out too far

I modified the battery holder model to include a 4mm gap behind the positive battery mount and barrel connector for my wiring. I built and tested the 18350 and 18650 cell holders, confirming the proper voltage from the barrel connector with a pair of DMMs.

Two battery holders and two good readings

I reprinted the internal switch component for the knife’s spine, which includes low-voltage switch nuts and high-voltage blade contacts. To secure the high-voltage wires without creating a narrow spark gap, I need a low-profile method instead of zip ties, which are too large to allow the internal switch component to slide into the tang.

That zip tie is not going to work

I hosted the show while Sarah was out sick, and we discussed The Land Before Time (1988). Amanda wondered why “Sharptooth” did not have a voice, and Fred and I listened. We missed Sarah and look forward to her return next week to talk about The Day After Tomorrow.

Critical Affection: The Land Before Time (55:00)

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
Completed projects from year 7
Completed projects from year 8
Completed projects from year 9
Completed projects from year 10
Completed projects from year 11
Completed projects from year 12

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