Hole and Plug test
thingiverse
To achieve a perfect fit between holes and pegs of varying diameters, I discovered that smaller sizes followed a consistent offset. For example, a 0.36" hole fitted a 0.30" peg, while a 0.30" hole worked with a 0.24" peg. By adjusting the test pieces by 0.06", all sizes aligned perfectly. Consequently, for a desired 0.25" rod, I now design a 0.31" hole that results in a 0.26" dia hole and a 0.24" peg diameter. Inventor files are provided to customize the sizes as needed. To verify the constant offset, print the templates at desired resolutions and test the fit; otherwise, expect varying differences based on hole size.
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