‘Metal-up’ those boring toggle switch tips.
avatar

Here’s a cool way to ‘metal-up’ the boring, generic old Switchcraft 3-way toggle in only a few minutes. Using only a drill and few hand tools, there’s many small plastic, wood or metal items that would make interesting and cool switch tips. Dice, board game pieces etc, are some obvious examples.

20150719_151221

In this case, it’s a rubber skull keychain from my late mom that has great sentimental value.

20150719_151254

Using calipers, measure the switch shaft diameter to determine the pilot hole size. Because we’re going to tap threads into rubber, we drill quite undersized so the malleable rubber grips tight to the shaft. I went with a 2.5mm bit.

20150719_151827

Measure the thread depth to the stop ledge.

20150719_154508

Tape off your depth-stop on the drill bit using this measurement.

20150719_154824

LOL. Now we shall CRUSH THE SKULL OF OUR HAPLESS VICTIM IN THE VICE OF VENGE-….um, place the piece to be drilled firmly in the vice.

20150719_155025

Lol. I mean seriously, is there anything not made there now? Bonus points for the anatomically-correct moulding job though. 😀

20150719_155105

Logically, we always drill in the thickest part and make sure the bit depth won’t penetrate through beforehand.

20150719_155306

Drilled out to depth. Ream slightly to clear the hole nicely of debris, but be careful not to widen much.

20150719_155401

Now a 6-32 tap (works for Switchcraft toggles) is used to gently cut some threads in the rubber.

20150719_160038

Clean out the hole of cuttings and gently screw on. Watch for clearance when switched over back and forth. In this case I had to slightly trim the underside of the skull where it made contact with the toggle nut, using an x-acto blade.

20150719_161109

😀  \\m//

20150719_161157

 

This entry was posted in Uncategorized. Bookmark the permalink.