My time as an engineer in the aerospace business taught me that using the right fasteners can have a huge impact to the functionality and serviceability of an item. Sure, a common pan head machine screw will work to hold an access panel in place. But using a custom screw with an oversized Rosette head allows an astronaut in a spacesuit to quickly remove the panel without tools. I'm sure you can imagine what a tremendous advantage that is.
I often find that specialized hardware can provide similar benefits with my RC projects. The main difference boils down to a question of availability. If the specialty fastener that I want is even manufactured, it is usually prohibitively expensive or is only sold in large quantities. Other times, I need a special fastener "right now". Ordering online or even driving to the hardware store just won't cut it. More often than not, I end up making my own specialty fasteners by modifying common nuts and bolts that I already have in my workshop.
In this article, I will illustrate my techniques for creating three different types of custom fasteners.
Whether I'm going on a week-long vacation or just an afternoon trip to the flying field, I tend to be a minimalist when it comes to packing. I take only the bare essentials and try not to weigh myself down with accoutrements to deal with "what if" scenarios. This probably means that I'll be among the first to succumb to a zombie apocalypse. Until that brain-eating day, I'll live happily unencumbered.
Translating my streamlined packing approach to RC means that I aim to carry very few tools with me. If a specialty fastener lets me do a job without tools, then I'm game. That's why I often find myself turning normal screws into thumb screws. If you're not familiar with thumb screws, they are fasteners that are designed to be turned by hand rather than with tools. Thumbs screws are super-convenient as long as you don't have high torque requirements…which I almost never do for RC applications.
Converting a common slotted machine screw into a thumb screw is very easy. You just make an appropriately-sized tab out of scrap material and glue it into the slot of the screw. The tab becomes your grip for turning the screw. I have a sheet of 1/32"-thick Kydex plastic that I typically use to make tabs. I have also used craft sticks, thin plywood and scrap aluminum for the same job. You're bound to have something that will work. GOOP adhesive is great for gluing the tab to the slot.