How to: make thermal detonator clips

[Pandatrooper]

Hi staff, I copied this from my SC build thread. I figured it might make a good "how-to" but if it was buried in a thread, people might not find it. Feel free to delete or move the thread if you don't think this is the right way to do this.

 

Hope this is helpful!

 

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So I wanted to make accurate looking TD clips. I have seen different solutions so far, and scoured stores. But I figured these would be easy enough to make, just takes some dedicated time. I have built plenty of screen accurate TK style thermal detonators, and I figured this would be similar.

 

I started with a 1" wide 1/16" thick aluminum strip. Same as I used for my TK detonators. I plotted out some measurements for the slots. You could use the same measurements based on the ruler in the next few pics.

 

I drilled some small holes on the end for mounting the clips to the hose, and to assist in the bends later on. I realized after the fact that one of the small holes was drilled in the wrong spot, but it's hidden under the belt.

 

The larger holes are the ends for the large slots. I made the small pilot holes bigger with a Unibit.

 

I cut the large slots out with my trusty Dremel and a fiber reinforced cut off wheel (wear safety glasses kids).

 

Used a file and some sandpaper to clean things up and straighten the slots.

 

I bent the longer ends into a curve, so that they can be screwed tightly into the hose (and through the ABS pipe that was glued into the hose caps - remember?).

 

The bigger bend was made by using the small hole in the other end, and folding the clip over a piece of 1/4" plywood. Make sure you make the bend at the top of where your belt sits (position may vary depending on how curvy you bent the hose end).

 

Test fit, looks good.

 

You can see how the clip will hang onto the belt on the back side. I think I made the bend even a bit tighter after this pic was taken.

 

I also bent the tips that go behind the belt inwards slightly, to prevent the clips from sliding easily. Same trick as seen on TK TD's.

 

I did a final sanding, washed the clips and cleaned them, then primered them and painted them satin black.

 

Clips screwed into the bottom of the hose. Job done!

 

Back of the belt on my duct tape mannequin. *Note: things might look a little big as I have a 30 waist. The mannequin's stuffing is a bit packed out, so the belt is "oversized" on the mannequin. The TD hose is also a hair shorter than I would have liked, but it will do.

 

TD installed via magnets and clipped in.

 

I stuck a piece of paper under the belt so that the belt clips would be visible.

 

 

Close up view, similar to the clips seen on the SC site.

 

[Southscout]

Nice!

[9506]

Thanks for that!

[Dart]

Wow! Thanks for the great tutorial! I'm diggin' the magnet mod too.

[Pandatrooper]

Thanks. Glad its helpful.

 

There is a step by step on the magnet mod in my build thread.

[lonewolf]

I think this looks great Terry, you are a great asset to BS.N, new blood, new ideas, we need this

[Griffin-X]

Very nice job and tutorial Terry. Well done!

[Pandatrooper]

Thanks for the kudos all! My machinist friend just had a baby, so he is away for a few weeks. When he goes back to work at his shop, I will ask if he is interested in doing a small run and the costs involved.