Hole and Plug test

myminifactory

I designed my parts with precision, but no matter what, the holes were always too small and the post too big. Since the pegs and holes are approximations made by straight lines, it's understandable that they don't match perfectly. I wanted to know exactly how much I needed to compensate for this discrepancy, so I created a fixture to measure my parts accurately every time. As it turned out, smaller sizes had a constant offset. The 0.36" diameter hole fit the 0.30" diameter peg, while the 0.30" diameter hole fit on the 0.24" diameter peg. By offsetting the test pieces by 0.06", all my holes and pegs fit together perfectly. Now that I know this trick, if I want to design a rod with a specific size, such as 0.25", I can simply design it with a hole of 0.31" diameter. The resulting peg will be 0.24" in diameter, and the hole will be 0.26" in diameter - a perfect fit. My parts range from 0.100" to 0.36" in diameter, in increments of 0.20". I've included Inventor files so you can adjust the sizes to suit your needs.