This is the second version of my Disc Detainer (DD) pick. This version is based of the amazing Silver Bullet tool created by Matt Smith (aka HuxleyPig). If you need a real professional tool for DD a verity of DD locks check out his tool - https://silverbullet.tools/

The design and construction of this tool is much simpler than the first version and it requires-

The standard version:

• 3d printed tensioner
• 3d printed manipulator
• standard M4 nut
• M4 screw of your choice, I am using 20mm but you can also use an M4 grub screw if you don't want it sticking out.
• 5mm OD 2 or 3mm ID stainless steel capillary tube (2$ from Aliexpress)
• standard M3 nut
• M3 grub screw
• 6mm by 2mm "Plastic Injection Component" (0.5$ from Aliexpress) aka Injector Pin

The 6mm version:

• 3d printed 6mm tensioner
• 3d printed 6mm manipulator
• standard M4 nut
• M4 screw of your choice, I am using 20mm but you can also use an M4 grub screw if you don't want it sticking out.
• 6mm OD 2 or 3mm ID stainless steel capillary tube (2$ from Aliexpress). If you are unable to find 2 or 3mm ID tube you will have to get 4mm inner diameter tube and another 4mm OD 2mm ID tube (this is what I did).
• standard M3 nut
• M3 grub screw
• 6mm by 2mm "Plastic Injection Component" (0.5$ from Aliexpress) aka Injector Pin

See assembly instructions in the next section.

If you want to modify something the model is available here: https://cad.onshape.com/documents/1ea3e75273ef245935902b9d/w/3dae917f5709ba7b69fabb1f/e/3fbcd0bb95d1397630dce2f7

Print Settings

Printer Brand:

Prusa

Printer:

I3 MK3S

Rafts:

No

Supports:

No

Resolution:

0.2

Infill:

25%

Notes:

4 perimeters for extra strength

Post-Printing

Assembling the tensioner

1. Take the capilary pipe and cut it to the correct length:

a) Stick the manipulator into the tensioner all the way in so that the pick is in its shortest length.

b) Insert the tube into the front hole of the tensioner until it is stuck in the manipulator.

c) Mark a line on the tube flush with the manipulator and cut there.

2. Create a flat area on the end of the pipe such that it fits a lock disc. It should be about 10mm into the pipe. If you are using the 6mm pipe it will create two prongs.

At this step you need to make sure that the tip is squared on all sides. If it will be wedge shaped it will pop out of the lock when you apply tension.

3. Grind a flat strip on the side of the pipe starting from the squared off end and of about 25mm length. It should be very very shallow and it is only there so that the screw can hold the pipe in place better. Note that it should be aligned with the flat part of the tip!

4. Insert the M4 nut from the front hole.

5. Insert the pipe with the tip facing out.

6. Screw the M4 screw to the hole on the side.

You can adjust the length of the tension nose length by releasing the screw and moving the pipe in and out. Adjust it so that it binds only the first disc and tighten the M4 screw tight.

Assembling the manipulator

The tensioner should be already assembled.

Prepare the pick tip from the injector pin.

The sizes I use are:

Width: 2mm

Length: 5.5mm

Thickness: 0.75mm

Note: The thickness must be thin enough so that you can negotiate your way in between discs which are 60 degrees apart from each other. This essentially means that it should be about the thickness of the separator disc.

Setting the correct length to cut the injector pin:

Note: Do not try to measure it by inserting the pin into the manipulator as you will need to cut the tip first!

1. Measure as much as you think you will need from the tip base. I usually do 30-40mm.

2. Insert the manipulator into the tensioner all the way in so that the tool is in its shortest form.

3. Align the mark from (1) with the end of the tensioner (you can use the end of the plastic part).

4. Make another mark on the injector pin about 1mm below the hole in the manipulator side.

5. Cut at the mark you made in (4)

To insert the injector pin into the tensioner you will need to grind off a flat area of 30 mm on the tip of the shaft (on the opposite side of the pick tip). Look into the manipulator body to understand how much to grind off.

Note: The flat area should be aligned with the long part of the pick tip to make the markings on the tool match correctly.

To assemble use the following steps:

1. insert the pick tip from the front of the tensioner until it sticks out the other end.

2. Align the manipulator hole with the end of the injector pin and insert it into the tensioner. You should see the tip of the injector pin through the hole in the manipulator handle.

3. Insert an M3 nut from the back of the manipulator.

4. Insert an M3 grub screw into the hole of the manipulator and tighten it.

Tip of the standard version

Tip of the 6mm version

Category: Hand Tools