I am still a novice, but I am trying my hand at an internal chassis and found that 3/4" gray PVC pipe is great size. It is pretty easy to pressure fit a battery and still have room for wires to pass through (I have channels made, just not shown). It also can be filed down to slide inside a speaker holder pretty easily. Plus, it gives you lots of room for layering effects and still fit inside a hilt.
But, most importantly for me, it is easy to manipulate (I only have a dremel and a hand drill) and you don't have to worry about shorts.
I know I have a LOT of clean up and finishing to do, but here are some in-progress pics showing how the main parts fit together.
(the white parts are a combination of a 1" plastic sink tube I found and plastic sheets/etc. from my old plastic modeling days.
very nice!
The chassis in Pathfinder is in SLS nylon ("Strong & Flexible") from Shapeways. I've been printing parts at home more and more parts at home, especially parts that aren't usually seen. Some inexpensive mechanical upgrades have dramatically improved the quality of my prints (better motor, more rigid supports, etc). There is a cost/aesthetic/capability trade off. Home printing, in the long run, can be far more economical, but the shape and complexity of the parts is more limited and the appearance isn't as refined or predictable.
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