Earlier in this thread, I pointed out the importance of documenting your failures. Yet, I have failed to do so for the LED star adapter.
It didn't just appear fully formed, I've been thinking about how to make this thing for months.
I started with a TCSS 7/8" heatsink. My first idea was to add a small piece of wire, inside the edge that holds the lens in. This wire would go most of the way around, but leave a space where a tool could be inserted to extract the adapter from the hilt. While this could potentially work, I did not have a tool that would fit, and the narrow opening is probably not going to work well with a 3d-printed tool either. Also, I tried 3d printing something that would hold the blade connector to the bottom of the heatsink, but could not figure a way to attach it securely. FAIL.
So, I drew up a second design, with the intent of hiring a machinist to make it. It looked like this: (sorry about the rotation)
This is a tube, threaded all the way through with three inserts, all threaded on the outside. The tool needed to extract the adapter would be threaded too.
A quick chat with an actual machinist, and I was told that threads are a pain in the behind to make, again FAIL.
Next design:
This one I was told wouldn't be *too* difficult to make on a lathe. It uses set screws to hold everything in place.
However, machinists are busy people, so I was told that maybe I could get it made in a few months.
I'm not very good at waiting, so I kept thinking about it, trying to come up with a design that I could actually make
myself, which is what led to the current design:
This one can be made with a dremel and a stand to hold it in place. Total success, it just took me three months to figure it out. :)