I have been on the road lots this summer, and heading out again. I have nice cases for my two paper planes, but I am trying to put together a travelling game set that is as small as I can make it. The cardboard Range Stick is not convenient, nor something I want to entrust to my packing and baggage handlers in airports. So, what to do... Make the stick in two parts!
I wanted to use threaded inserts and do this like a pool cue, but there weren't any small enough to do this with the orange sticks I wanted to use for the finished product. My better half suggested a few ideas (constructive ones, actually), and I came up with the idea of carving a "puzzle" pressure fit joint. Well, orange sticks are really, really hard wood! Carving it and sawing it by hand was very difficult. So, I wanted to try this out on something softer, as a trial. I found some chop sticks in the house, and remembering someone had done up range sticks with chop sticks, thought that this would work for me, too. Bamboo is not soft! It is only a bit softer than orange sticks, but it was easier to work with.
So the sawing and carving began in earnest. And I messed up the joint really bad. I was trying to engineer this in my head, and with 2 dimensional drawings, and that wasn't working. So, carving and sawing was the only way to see if the plan would work. Second try, and I got really close. However, the pressure fit was off (loose and crooked), and without re-carving from scratch, I could try doing just one side (again) to see if that would fix it (not likely). Then I remembered that I have some fine brass rod, and I could pin the loose joint and straighten out the stick, without redoing the whole thing!
Pictures are below:
This is after carving and pinning the two halves. I drilled through one side of the joint into the other side, but not all the way through. Then, inserted and glued a brass rod. Test fitted it, and then cut and filed the brass cut smooth to the bamboo.
This is the comparison with the real Range Stick, unpainted and painted:
And this is how it goes into the box, with the plane:
Hope this is useful to any other pilots who are on the move and need to keep things small.
Signing off,
OldGuy 59 (Mike)
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