Wedge Expanding Plug for 1.5-in Square 13-ga. Tubing

prusaprinters

Add that finishing touch to your square tubing project! Keep bugs and dirt out of the tubing. Screw-tightened wedge to ensure solid retention. Square wedge to prevent rotation. Print layer height, fill percentage are flexible. Support is not recommended.Installed print shown is 0.35-mm layer height, 30% fill. Material is ABS,  though if I did it again, I would use ASA for improved UV resistance. This could easily be modified for heat-set insert.The only post processing step is to lightly sand the edges of the wedge to reduce the layer definition. This will make the wedge slide more easily in the plug when you tighten it up. You may need to clean up the hole for the screw with a #32 or 3-mm drill bit, and possibly touch up the countersink with a 90° countersink tool.If using 0.35-mm layer height, pause at 7.2-mm to insert a small pattern thin nut (90710A030). Use a M3X20-mm flat-head screw (92010A128) to pull the wedge tight and expand the plug in to the tubing. Longer screws will work too (part as installed uses  92125A138).