Playschool Pipeworks: Pipe Manufacturing Kit

This kit has all the tools you need to select the proper PVC pipes, and drill the holes for the PipeWorks playset. 

WARNING! 

Not all PVC pipes are the same size so using the tolerance tool is CRUCIAL when buying the pipes. otherwise you will waist hundreds of dollars (trust me bro).

Pieces in this kit:

1x Tolerance tool

2x Drill templets

1x Workholding pin ("the pin")

STEP ONE:

Print the kit in the same filament you will be printing the parts in later. 

this will limit tolerance issues later, but is still not foolproof. 

ALWAYS REMEMBER TO CHECK YOUR FIRST BATCH OF POARTS BEFORE MASS PRINTING. 

STEP TWO:

Take the tolerance tool with you to whatever hardware store you buy your PVC from. 

Test the inside and outside of the 1 ½" PVC to make sure the parts will fit. 
Inside tolerance SHOULDN'T be snug. it should slide in with minimal gap (1mm or less), yet SHOULD NOT rattle when shaken side to side. 

It's a feel you will understand when you get other parts built, so its not a bad idea to start with one pipe, and come back later for more once you get an idea for how it should fit with other parts. 

Outside tolerance SHOULD be loosely fit. This part is supposed to hold itself in place, but still be easy to slide. 

the outside dimensions of PVC are (in theory) standard while the inside is not. so if the tolerance tool is too tight, you may be having an issue with the filament causing imperfections that are messing with the tolerances. 
IF YOU GET THIS RIGHT THE REST OF THE BUILD SHOULD BE EASY!

STEP THREE:

Cut pipes to length.

Long pieces are 13 7/16ths (342mm)
Short pieces are 5 3/8ths (137mm)

These lengths need to be as precise as they can be, because 2 short pieces joined with a connector is supposed to equal one long piece. 

Its best to use a chop saw with a measured end block to insure consistent lengths.

STEP FOUR:

Drill the holes.

Slide a drill templet on each side of the pipe, and using a level surface, push them flat so that they are lined up properly. 

look through the inspection port to make sure the PVC is seated all the way back in the templet. 

Using a 5/16ths drill bit, carefully drill the first hole, using the templet to guide the drill bit straight down through both sides of the PVC. 

Its best to take this step slow, so you don't melt the print or drift off course. 

Insert the pin into the drilled hole to hold templet in place, and double check that the templets are lined up by pressing them on a level surface, and that the pipe is seated properly by looking in the inspection port. 

Then drill the second hole. 

Take your time, this is going to be a long process.