Wedge Expanding Tubing Plug for 2-in Square with 3/32-in wall

prusaprinters

Add that finishing touch to your square tubing project! Keep bugs and dirt out of the tubing. This was inspired by my twin sister's stream of curses after being stung by a wasp that lived in the tubing in her backyard bench. She can really paint a colorful picture with bad words! Screw-tightened wedge to ensure solid retention in the tubing. 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, 50% fill. Material is PETG,  though if I did it again, I would use ASA for 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 an imbedded small pattern thin nut (90710A030). Use a M3X25-mm flat-head screw (92010A130) to pull the wedge tight and expand the plug in to the tubing.