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Originally Posted by Long Haired Git
..Nah - my block will be very cheap. Just the material cost of a copper top is more expensive than the machined acrylic top, let alone the effort to drill and tap barb holes.....
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So, when you machine the acrylic top, why don't you make a oval or rectangular (the last one is easier/cheaper to produce) chanel for the O-Ring right into the acrylic ?
If your top is thick enough, and you leave adequate space between the O-Ring's channel ane the acrylic sides - the construction will be quite strong.
Despite of the thickness of the O-Ring, it can be smashed so the two parts of the block will be practically touching each other IF the channel is accordingly machined. How to do this - look at the attached drawing (a well known picture about O-rings indeed, and I've tested it with a lot of them).