I finally had a chance to cut my notches on Saturday, after learning that the notches need to be adjusted based on the individual piece of Delrin. I adjusted the dimensions for a certain piece and made the notches. I found that the best tight fit resulted from a hole that is .2 mm smaller than the measured thickness of the Delrin. Using this strategy, Julie and I constructed our windlass with tight notches that snapped in to place!
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