How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

Chappers wrote:

How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

O-ring or some type of springs (kinda leave spring).

Nick
--
Motor Modelle // Engine Models
http://www.motor-manufaktur.de
DIY-DRO // Eigenbau-Digitalanzeige
http://www.yadro.de

Chappers wrote:

How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

Has David Steele run out of ideas?

http://www.aluminium-lighting.com/company.html

eh?

How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

Slip the item inside the tube to the proper location, then use a small
punch to dimple the tubing from the outside at both ends of the
inserted item.
Ken.

Has to be able to be hand fitted inside the tube, no deforming the tube
itself inside nor out

How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

If you can't bond it or bolt it, friction is your only other option.

I'd suggest and expanding split circular piece just smaller than your ID.
Just cut the tube in one spot. Attach a small turnbuckle (rigth and left
hand screw with nut in middle) to expand against ID

Karl

Chappers wrote:

eh?


Are you really the teaboy trying to make an impression?

Ha Ha! Nope!

"Chappers" wrote in message
oups.com...
How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight


I assume that by "no bolts" you mean "no bolts that go through the tube".

Large rubber bung with a hole in it, a pair of large thick washers almost
the diameter of the tube and a bolt that is long enough that you can do the
following:

Slot the theaded end of the bolt (hacksaw) for a screwdriver.

Bolt through the washer-bung-washer sandwich, head of the bolt on the
inaccessible side.

Wingnut on the accessible side.

Keep the bolt from turning with a screwdriver, screw down the wingnut. The
rubber will expand and grab the sides of the tube.

You can use the same bolt to hold your device.

You neglected to state whether it has to be (readily?) removable, high or
low precision, or if this is a one-off application or a production lot !

That said, a piece of wire, slightly longer than the inside diameter of the
tube, held at its midpoint and forced into the desired location and oriented
across the ID of the tubing. The inserted wire will be slightly bent and
the bend will be free to pivot about the diametral line through its end
points.

Or, with more holding force and potential for precision, a thin sheet metal
washer similarly inserted. Washer may need to have radial slits spaced
around its outer edge to reduce the insertion force and may be nearly
impossible to remove without significant damage. On the principle of
commercially available threaded inserts for common small sizes of tubing
(e.g., http://mappcaster.com/mall/Inserts-For-Round-Tube.ASP). You may have
to make your own for larger sizes.

Or, a piece of wire, slightly shorter than the internal circumference of the
tube, formed into a split ring whose outer diameter slightly exceeds the
inner diameter of the tubing, compressed and forced into the tubing to hold
by friction or into an internal groove for greater precision and retention
force. Also commercially available.

David Merrill


"Chappers" wrote in message
oups.com...
How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

A simpler way to expand the split sleeve is to tap a hole parallel to the
axis of the tube where you plan to slit it with a taper tap, tapping only
part way through the sleeve. Then slit the sleeve through the tapered hole.
When you drive a set screw into the hole, it will expand the sleeve and lock
it inside the tube.

--
Bob (Chief Pilot, White Knuckle Airways)


"Karl Townsend" remove .NOT wrote in
message anews.com...

How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

If you can't bond it or bolt it, friction is your only other option.

I'd suggest and expanding split circular piece just smaller than your ID.
Just cut the tube in one spot. Attach a small turnbuckle (rigth and left
hand screw with nut in middle) to expand against ID

Karl

What about the tapered wedge that holds the front handle bar stem
on a bicycle? Simple, holds well, easy to adjust.


______________________________
Keep the whole world singing . . . .
DanG (remove the sevens)




"Chappers" wrote in message
oups.com...
How would I secure a device inside an Aluminim tube - it has to
be hand
fitted and practical to use. No bolts, glue or welding
suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in
weight

Chappers wrote:
Ha Ha! Nope!

Is this some sort of game?

"Chappers" wrote in message
oups.com...
How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight



Make a thick (.375-.5") washer about .002" smaller in diameter than the
inside of the tube. Drill and tap the end for a 1" tapered pipe plug. Cut
the washer almost the full length of the washer with a band saw through the
center of the tapped hole. If you would like, you can rotate 90 deg and make
another cut so that the face of the washer looks like a sliced pie. You have
just made an ID collet that is tightened by inserting a pipe plug.

Chappers wrote:
How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight


It's really so simple I'm surprised you had to ask.

Hold the tube in your right hand. Pick up the device with your left,
and quickly insert it. The heat from your hand will expand the tube,
and when you remove your hand the tube will shrink on the device. To
remove it, just expand the tube with the heat from your hand.

What could be easier?

John Martin

jtaylor wrote:
"Chappers" ... wrote ...
How would I secure a device inside an Aluminim tube - it has to be hand
fitted and practical to use. No bolts, glue or welding suggestions
please.

Diameters range from 114mm - 202mm

The device itself is circular and lightweight, approx 2kg in weight

I assume that by "no bolts" you mean "no bolts that go through the tube".

Large rubber bung with a hole in it, a pair of large thick washers
almost the diameter of the tube and a bolt that is long enough
that you can do the following:
[snip howto]

For off-the-shelf versions, see pages like
http://www.newmantools.com/cob/pipeplugs.htm
-jiw

Chappers wrote:

Ha Ha! Nope!

So this mission statement from your company's site is BS?

"ALC Objectives

ALC operates a policy of:

Offering a customer-friendly dealing environment
Offering high quality products
Full product compliance with all current UK and European standards
Carrying high stock levels to give short lead times
Offering full design and technical support
Early adoption of new technologies to maintain product superiority"

You or the company, actually trawl the 'net soliciting advice on how to
comply with the above?

The Company capabilities are bogus too?

"ALC Capabilities

Over a period of years, ALC has developed a wide range of manufacturing
capabilities. This development has been
driven by our strategy of offering superior products, absorbing new
technologies, and finding the innovative solutions
needed to satisfy the expanding demands of the market in standard range
choice. Special project requirements are
addressed by our capability in designing bespoke solutions.

ALC in-house production includes:

3-D visualisation to determine design style
Computer aided calculation to verify compliance with BS EN40
Specialist cutting, bending and welding techniques
Component machining for precision fit
Specialist machining techniques relevant to aluminium material
Specialist packing methods to ensure safety in transit"