Greetings everyone. I have been lurking on the boards for some time learning and planning out a build before finally taking the plunge and ordering parts back in the fall. Finally, in the past month or so I've been working (slowly) on actually building my first saber.
For this saber I am using TCSS chassis disks and 4-40 all thread to build my chassis. I have almost completed it, however I have discovered that the brass 4-40 nuts overlap the edge of my chassis disk style 3 pieces by about 1mm (meaning the chassis will not fit into the Ribbed V-Grooved section they need to without a small modification).
I figure there are two ways I can go about it:
1: I can simply sand off the offending 1mm edge of the brass hex nuts (simplest -and safest- approach, but I am worried this may make future disassembly/re-assembly of the chassis more problematic since I will be rounding off the hex nut)
-or-
2: I may be able to (*very* carefully) file out a tiny 1mm channel inside each side of my ribbed v-grooved section to provide the needed room for the hex nuts to slide in as they are now (this option would mean no damage to hex nuts making future disassembly/re-assembly of the chassis less problematic, and might also have the added benefit of discouraging the chassis from trying to rotate as I tighten down the sections locking it in place. Of course I know this would come at the risk of filing too much material away from the part and creating a hole/structurally weaken the part if I am not extremely careful).
This brings me to my question: can anyone who has knowledge tell me what the measurements are between the thinnest outer part of the ribbed v-grooved extension (in the valley of the v-grooves) and the inner wall of the pieces?
At present I can estimate the thickness, but since I've not actually cut a hole into one of these sections before I'm not sure if my estimate is terribly accurate and I assume there are multiple veterans that have had experience using this extension piece in various ways.
Thanks in advance for the insight.
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