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The aluminium structure

A project log for Gauss rifle v2.0

An improved version of my first gauss rifle.

pinomeleanPinomelean 02/15/2017 at 10:480 Comments

The barrel and coils are somewhat flexible by themselves, so they need something to keep them straight and give some rigidity to the structure.

In v1.0 (picture above) i used anodised aluminium T profiles as both busbars and structural elements. They proved to work well as the structure for the barrel, but they presented a few problems as conductors.

Even with the thick oxide coating, shorting of the busbars happened a few times, and given the power that the batteries can deliver it made for quite a firework show. Also, such a thin aluminium profile doesn't hold threads very well; tightening a screw a bit more than necessary would tear them right off.

As i liked how well they fit over the coils and kept the barrel straight, i decided to use them again for v2.0, but with a few changes in design.

Instead of screwing the profiles to the spacers as in v1.0, i decided to glue them in place to give the gun a cleaner look.

The T profiles are 15x15mm. This size leaves the sides of the coils visible.

This time i decided to use copper busbars to carry the current instead of the aluminium profiles themselves. I looked for 4x10mm or 4x12mm copper profile, but i couldn't find any so i had to use trimmings from 4mm copper sheet.

In the top and bottom, the profiles leave a gap that allows the coil wires and photodiodes to come through, and a nice pocket to place the busbars and PCBs.

I also like this kind of profiles because they're a good place to fasten other components to the rifle.

Like the solenoid that feeded the projectiles from the magazine in v1.0.

In v1.0 the gun handle, the battery holders and the strap rings were also bolted to the T profiles.

In the v2.0 rifle i plant to fasten things in a similar way, given how easy it is to tread this aluminium profiles. , and how convenient the spacing between them is.

I just have to be careful to spread loads along many bolts because as i said, any excessive force will destroy the aluminium threads.

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