Ideas:

  • Switch to a single pathway into one capsule instead of a branching fitting into two capsules
  • Sandwich aluminum burst disk between two fittings and thread a modified firebolt (or two, for redundancy) into it
  • What pressure are the gases from the black powder?
  • TO-DO: Test sealing the e-matches in with hot glue instead of epoxy, would make integration less hazardous/quicker and re-use possible
    • UNSUCCESSFUL, hydrostatic test resulted in leaking through the hot glue
    • Could have been from a poor seal, but hot glue cools quite quickly and it doesn't flow to seal gaps as well as epoxy
  • Design 1: 
    • Reducing adapter 50785K612 (3/8" F x 1/8" M)
    • Plug w/ ext. hex drive 50785K23 (3/8" M, hollow)
      • Drill two holes for two e-matches
    • Burst disc
      • (Heavy duty?) aluminum foil with maybe an o-ring or something to hold pressure (might just work without it though, could use RTV gasket if necessary?)
      • Tape (aluminum duct tape, maybe just regular tape would work) 
    • Angled washer to promote good sealing
      • 3D print with a softer material (flexible resin? TPU?)
      • Faucet washer: 2801K24 (kinda thick and not exactly the right angle/diameters)
Prototype Design 1:

  • Design 2:
    • Drill one slightly bigger hole instead of two holes to reduce machining time
    • Replace the aluminum burst disk and instead add 1-2 printed layers to the angled washer to act as the burst disc
      • Sealing on the washer probably not necessary, it just needs to contain the black powder granules, not be an airtight seal
      • Can probably just print in PLA on an FDM printer (cheap and easy!)

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