Bo Deadly
Well-known member
I want to make two spacers to retrofit a bantam jack into a double layer panel that looks like this:
So the panel is 1/8" w/ 0.55" hole (shown in green) + 1/16" w/ 0.375" hole. The trick is how to mount that bantam jack into that hole.
I could drill a hole w/ countersink into the 1/16" panel but there are multiple problems with that so I won't get into it.
The best I could come up with is making parts like the above graphic. So the bantam jack would bolt onto the spacer nut with a 4-40 screw (holes are outer diam). Then a flange spacer (shown in black) threads into that through the panel and clamping the whole assembly in place.
However, the eMachineShop software reports that the two threaded holes are too close and that the material between them may become deformed or missing. This part is behind the panel so I actually don't care so much. It seems a slot could be cut between the holes like one might do with a clamp. Although I don't know how to actually make a threaded "clamp" because after I add the slot, I can't figure out how to thread the hole as it is no longer just a circle.
Also, EMS reports that even the 3/8-24 thread on the boss of the flange spacer (shown in black) is too close to the 1/4" bore. But it seems to me it should be possible to thread a 3/8" boss with a 1/4" bore. There's plenty of meat there.
Finally, another issue is that EMS wants 1 million USD to make these parts (and that's after the "student" discount).
Does anyone have any ideas?
UPDATED in Reply #4
So the panel is 1/8" w/ 0.55" hole (shown in green) + 1/16" w/ 0.375" hole. The trick is how to mount that bantam jack into that hole.
I could drill a hole w/ countersink into the 1/16" panel but there are multiple problems with that so I won't get into it.
The best I could come up with is making parts like the above graphic. So the bantam jack would bolt onto the spacer nut with a 4-40 screw (holes are outer diam). Then a flange spacer (shown in black) threads into that through the panel and clamping the whole assembly in place.
However, the eMachineShop software reports that the two threaded holes are too close and that the material between them may become deformed or missing. This part is behind the panel so I actually don't care so much. It seems a slot could be cut between the holes like one might do with a clamp. Although I don't know how to actually make a threaded "clamp" because after I add the slot, I can't figure out how to thread the hole as it is no longer just a circle.
Also, EMS reports that even the 3/8-24 thread on the boss of the flange spacer (shown in black) is too close to the 1/4" bore. But it seems to me it should be possible to thread a 3/8" boss with a 1/4" bore. There's plenty of meat there.
Finally, another issue is that EMS wants 1 million USD to make these parts (and that's after the "student" discount).
Does anyone have any ideas?
UPDATED in Reply #4