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Just as a quick follow up...the #7 plugs and a lot of packaging tape did the trick with the ferric chloride. I tested it on a couple of pieces before holding my breath and etching my TCSS parts. Great success!!
Thanks again for the tips guys. I'll have pictures of the final saber soon.
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Modeling clay is what I've been using. The clay that doesn't harden. Is inert in both copper sulfate and ferric chloride solutions. Can even be used in small screw holes, the cleaned out with soap and water. Clay is reusable.