4 replies to this topic

[Zorns Lemma]

You will need:
- 8-32x aluminum stanoff
- 8-32x machine screws
- metal rod
- 1.5" sink drain extension tube
2x- 1" to 1/2" PVC slip type bushing
- 1.5" neoprene washer
2x- steel washer 1-1/4 OD
- #8 washer

Start by sanding the fuck out of your shell, removing most of the ridges.

You want it such that the 1.5" drain pipe will fit snugly all the way back to the rear piece with the supports for the stock BBB plunger fins. Also, you can see that I extended the slots for the locking tabs by 1.5"

Plunger tube

Cut your sink drain to 10". This assumes that the bushings you have are 1.5" long like mine.. Cut off a further small ring from the unwanted section, cut it in half, and attach it to the pipe via PVC cement. It should fit like so.



Next, take one of the slip bushings cut it to .5" starting from the smaller end (thus you cut off the rim) and slam it into the back of your pipe.


Drill holes through the pipe and bushing for your metal rod. I drilled 3


Insert metal rod through these holes and cut them flush. The metal rod should be flush with both the inside and outside. Epoxy them in place.


This forms your plunger tube and spring rest.

Plunger rod

Next, cut your stock plunger rod until you're just left with the fins. You will need to also take out a section of the square that forms the plunger rod such that it forms just a +


Take 10" of 1/2" CPVC and cut 4 1.5" slots to fit the fins of the old plunger rod. Epoxy it all together


At the other end of the CPVC, drill a hole throught 1" down for more metal rod and add it in, again cutting flush. The rod should go all the way through. Epoxy it.


Put epoxy on the end of a standoff and shove it in, such that it attaches to the metal rod. Then fill in the space with epoxy putty


The plunger head is conveniently the same as the longshot replacement plunger head


Final plunger rod

Edited by Zorn's Lemma, 24 July 2009 - 11:28 PM.

[Zorns Lemma]

Final touches

Add epoxy putty to the rear shell to extend the "catch" area


The other bushing will be shoved into the other end of your drain pipe

Of course, you want to add this after putting the plunger rod through, putting on the spring, and screwing on the plunger head

Make sure the top row on the forward shell is completely clear for passage of the top cylinder on the rear shell


Final internal assembly


External shot at full extension


This takes 8" of a +bow spring and has 6" of draw.

Edited by Zorn's Lemma, 24 July 2009 - 11:21 PM.

[sam]

Haha you did this in the hotel room!
Pretty cool looking, we'll see how it performs tomorrow.

Edited by sam, 24 July 2009 - 11:52 PM.

[BustaNinja]

Nice. You did a hotel writeup. So who all is/was at the post war hotel stag party?

Da Stanky Leg

This is for you Sam.

Edited by BustaNinja, 25 July 2009 - 12:01 AM.

[2iko]

Dear God I have a new project for my BBB...