Float Switch holder DIY

[Intheflesh]

I have to say first that this is not my design; I am not this clever lol. I saw this on RC and decided I wanted to build it instead of buying a manufactured switch holder. The end result is a 2 switch holder that is adjustable (high - low switches):

Materials were from McMaster Car, and the switches I got from Amazon. I already had 2 switches, and ordered 2 more. The second pair I ordered are a different size, and will work for this project, but I did not have the right thread tap to tap the pipe.

Materials:

48855K41 Thick-Wall Dark Gray PVC Unthreaded Pipe, 1/4 Pipe Size X 5' Length, Schedule 80
94323A840 Nylon Thumb Screw with Shoulder, 1/4"-20 Thread, 3/4" Long, Black, packs of 50
8740K26 Chemical Resistant Type I PVC Rectangle Bar 1" Thick, 1-1/2" Width, 1 ft. Length

First step I cut the acrylic into 2" long blocks. I used 3. 1 as a prototype, and 2 to use.

I marked my lines for where I wanted to drill. For the prototype I did 1/2" in from the short side, and 3/8" in from the long side. I dont have a drill press, so I actually marked the other side too. I drilled a pilot hole about half way down, turned the block over and drilled from the other side. This assured me that my holes would be at a nice 90°:

Since I don't have a router table, I used table saw to cut the lip:

Then used shims against the fence to cut the channel to the appropriate width (about 5/16)

 

[Intheflesh]

Next I drilled out the 5/8" holes for the 1/4" PVC pipe to fit in. It was at this point that I realized 2 things: 1) I drilled to close to the long edge, and there wasn't enough material to cut threads. 2) I cut the channel too deep, and this actually forced me to cut the 5/8" hole too close to the edge.

Here's the completed protoype. Note the thumb screws on the front face, and how there isn't much material for the threading.

 

[s_kelley]

Wow, I'm impressed. Mine is some bent acrylic w a hole drilled in it lol

 

[Intheflesh]

So, I took not of my mistakes and started working on other 2. I didn't cut the dado as deep, which allowed me to push the 5/8" holes further back, and allowed for there to be more material for threading:

Here's the finished product:

I threaded the inside of the 1/4" pipe with 5/16"-18 threads. This worked for the 2 smaller of the float switches.

I will either need to buy 2 more of the smaller float switches or get the next size up tap if I want to use the large float switches.

 

[Intheflesh]

Wow, I'm impressed. Mine is some bent acrylic w a hole drilled in it lol

Thanks! My other half was out for the night, so I thought I'd have a little project night.