square tube end caps

[gaz_moose]

the company i work for have had a product made that they have designed but they have cocked it up. its basically a 25mm box section door that fits tightly inside a frame but they haven't mitred the corners and just did them the lazy way. now H+S are saying the hole is a pinch point so i wondered if there was a cap on the market that fitted flush?

like these ones

https://uk.rs-online.com/web/p/prod...VDrHtCh32NAxLEAQYASABEgIUH_D_BwE&gclsrc=aw.ds

but with less protrusion.

they have already made about 20,000 of them so someone somewhere is getting sacked for it, but if i can come up with a nifty solution then im quids in. i only really do automotive fabrication so this type of stuff is an unknown world to me.

 

[jsf55]

I've never seen flush one, but we used pyramid type similar to these if it helps, nothing to do with me !
https://www.bpfonline.co.uk/show_product.asp?id=809&catid=10741

 

[500e]

Skiffy Plastic & Metal parts
They do a whole range of strange bits
T 01902894658

 

[gaz_moose]

those pyramid ones are going to sit too tall sadly.
i will give that skiffy a look now

 

[Revs1972]

So that's 20,000 doors needing 4 end caps per door ?
So that's 80,000 end caps ?

Might be worth contacting your local plastic injection moulding company for a bespoke product. There will be tooling costs no doubt , but will probably work out fairly cheap per unit . And save a heck of a lot of doors getting thrown away lol

What thickness box is it ?

 

[Arclikeharrypotter]

Not sure exactly how an end cap would work flush, the nature of them being that the end stops them falling through. Potentially you could get a nylon square say 40mm deep and use a hammer to fit, tight enough it wouldn't pop out.

 

[Stingray]

Just give the HSE guy a backhander, however the way you define that is totally up to you...

 

[tlovatt]

Have a blank made and drill a hole to put a retaining screw through the side

Failing that, some gorilla tape - you can leave them the rest of the roll as a 'free maintenance kit' as a gesture of goodwill

 

[Revs1972]

These puppies look like they have a very thin head. What's your clearance gap ?

https://www.vital-parts.co.uk/thin-head-square-inserts---sq103-2990-p.asp

 

[rtbcomp]

Fill the sections with expanding foam and smooth off at the ends.

 

[Kent]

OK no picture to go off but could it not be capped on TV e corners with steel caps welded ?

If they are galvanised and thin wall I would have done them open especially in the quantity spoken of. Its really up to the clients to specify not the makers in industrial subcontract work sent out.

Drawing, spec, tolerances

 

[pedrobedro]

Knock a piece of bar in and tack it. Nice little job for someone cutting it up and spotting it in.

 

[bigegg]

Fill the sections with expanding foam and smooth off at the ends.

i was going to suggest silicone sealer
less work/mess.

 

[tlovatt]

Can you get and of the tapered square rubber feet that are the right size to knock in with a mallet - they may drop out over time though?

 

[8ob]

You could make a simple punch out of a sharpened piece of 25mm square tube that sliced off the shoulder of the standard bung.It would only take seconds.

Bob

 

[merryman]

Ross castors make something like you need. https://www.rosscastors.co.uk/tube-...inserts/chrome-effect-square-tube-insert.html

Or Sinclair & Rush will make tube inserts to your design. I have used both firms and they are good to deal with.

 

[gaz_moose]

only just had the time to pop back here and comment, ive been totally manic.
the items are already built and galvanized. at first i thought it was going to fall on me to 'fix' them all hence why i was looking for a simple push fit cap but they are going elsewhere so i just put forward the idea of filling the ends with sikaflex.

cheers for the suggestions guys.