The Mortician

[Silver Serpent]

I've used aluminum tape as filler before to help get parts fitting snugly. It doesn't compress over time, so a snug fit today is a snug fit a year from now.

[Kreyhn]

Oh! Well now that I look like a schmuck, let me apologize for taking your unbridled enthusiasm as sarcasm. I guess it's hard to tell when it's just written.

But yeah! If something is just a slight bit too large, some thin tape on the inside can help shrink down the ID of the outer part for a nice snug fit. You could also do tape on the inner part to enlarge the OD; whichever fits your fancy.

Edit: like what Silver Serpent said.

[FenixFire]

PVC is fairly easily heatformed with either an old electric heater or heatgun. Though it off gasses fairly toxic fumes so respirator and outdoors... If the design is split like this you might be able to stretch a 1.25 enough to fit. If you cut a slightly larger section out you might be able to shrink it enough to fit by heating it "evenly" and then tightly wrapping the hilt and instantly quenching in room temp water.

[FenixFire]

I've used aluminum tape as filler before to help get parts fitting snugly. It doesn't compress over time, so a snug fit today is a snug fit a year from now.

I am doing this as well to snug up a joint on my newest due to having to slightly overbore the crystal chamber so it could slide in easier.

[CET]

Oh! Well now that I look like a schmuck, let me apologize for taking your unbridled enthusiasm as sarcasm. I guess it's hard to tell when it's just written.

lol, no worries. I can see how you might have gotten that impression. I get really excited by creative ideas that seem counter-intuitive to me.