how am I supposed to fit the 2.1 switch craft recharge port into my saber?

[phook15]

I have a 1 inch sink tube with a hole drilled in about 2 inches in. When I try to fit the recharge port in it's too big for the recommended 5/16 hole. I can't fit it in from the inside either because it's too tricky.

[Greenie]

It's meant to be fitted from the inside. :)

[phook15]

So I have to drill a hole thats close to the end of the tube?

[Greenie]

Is the hole threaded or are you securing it with the nut. If the latter, you could maybe hold it in place with needle nose pliers and screw the nut on from outside.

Can you post any pics?

[phook15]

The hole isint threaded. But I can go get a tap for the 5/16 at home depot.http://m.imgur.com/7kEBvzj

[jbkuma]

You could possibly use a larger hole, tap that and use a bushing if you can find an appropriate size.

[hapki]

Once you solder the wires on it, you're going to have trouble turning it inside the tube. I think Greenie has the right idea--making the hole just big enough to slide the recharge port into from the inside. Then you can secure it with hold it in place with a nut from the outside. That way you won't have to turn it.

[phook15]

Yeah, that's the method I just tested on it and it works. Twisting it would be tricky.

[Jay-gon Jinn]

you could do what I do....get a 1 1/4" pvc sinkdrain extension from your local hardware store, cut off about 3/4" off the end, drill and tap it for the recharge port, and cut through the ring to create a c-clip (for ribbed extensions, you need to cut off a bit of the ring until it fits):
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Novastars%20Saber%20Modifications/000_0007.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Novastars%20Saber%20Modifications/000_0008.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Novastars%20Saber%20Modifications/000_0009.jpg

http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Novastars%20Saber%20Modifications/000_0010.jpg

Use a flat screwdriver to snap the overlapped edges flat, and it's secure.

Drill a hole large enough in the hilt for the threaded portion of the recharge port to fit through (5/16") and you'll have flush mounted recharge port:
http://i119.photobucket.com/albums/o141/Jay-gon_Jinn/Novastars%20Saber%20Modifications/000_0011.jpg

[Silver Serpent]

Jay-gon's C-clip method works for some of the smaller tactile switches as well.

[snilam]

yes jay-gons methods works great! I've done it several times. Never seen it posted before but I was sure I wasn't the only one that did it. Its great for those holes that are way inside a hilt. Or smaller ID parts where rotating the jack will be much harder. I usually end up using it on 1" ID parts and with spare bits of blade material. Once in place its not going anywhere.

[Quixotic Jedi]

The hole isint threaded. But I can go get a tap for the 5/16 at home depot.http://m.imgur.com/7kEBvzj

They don't sell those taps at Home Depot. These recharge ports use a 5/16 - 32 tap, the ones they sell at Home Depot are 5/16 - 18. You'll have to go to a machiinist supply house like MSC Supply or Enco.

[jbkuma]

You should be able to simply drill an appropriate hole and let the threads in the port cut into the plastic.

[FenixFire]

They don't sell those taps at Home Depot. These recharge ports use a 5/16 - 32 tap, the ones they sell at Home Depot are 5/16 - 18. You'll have to go to a machiinist supply house like MSC Supply or Enco.
Might also try Ace, TrueValue, Tractor Supply, Rual King, Fleet-Farm, etc. they usually carry fine thread taps and dies.

[CET]

Just a reminder that TCSS has a chassis recharge port system. http://www.thecustomsabershop.com/Acrylic-Chassis-Disc-for-Recharge-Port-S8-P772.aspx