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Originally Posted by Cathar
I had a few closeup pics, but they are a little fluffy on the ends due to using very old cutters. The tool used to cut the delrin tubes had already been through about 40 of the G4 copper plates. Just a prototype here so it's not "picture perfect".
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Discovered what was wrong with the G5 prototype middle plates. The machinists accidentally used a 33% larger cutter than intended to cut the tubes out. As a result the tubes on the G5 prototype middle plates have a wall thickness of 0.10mm, as opposed to the intended 0.35mm thickness. Quite frankly I, and correspondingly the machinists, were somewhat amazed that we were able to reliably form 0.1mm (~1/256" for you imperial boys) wall thicknesses with the Delrin. Machinist then groaned as he realised that this probably now meant that I would walk in with a design one day that called for 0.1mm thickness machining with the confidence that it can actually be done reliably.
Will be getting replacement G5 middle plates in the next 8-10 days.