Argh - sorry to hear about the setback.
Sorry about your mis-hap RBD! Hope you get rollinā again soon!
Thatās what my wife would think. Is it possible that we are both married to the same woman?
Sorry to hear about the mishap. They say a bad sprain can sometimes hurt more than a broken bone. Hope you heal fast.
Me too. I passed out walking to stick it in ice water. Came to ~20ā from my last conscious position. Took about half an hour to pull myself together. First 24 hours was ice packs an now Iām alternating with compression bandage and heat. Wilma has me locked out and I canāt reach my beer though. :cry:
While this is healing Iāll continue to do what little I can which doesnāt seem to be much since I need my hand more than my elbow. I was able to use that elbow to finish the siding job where I got the injury. A smallish job ~ 250 square FT of hardi plank. 
I had to finish the areas above the windows and garage door with the bum hand. Climbing ladders with a plank and a nail gun. Iām just glad itās done. After that youād think a half gram switch mod would be easy. These are my options; a mini omten and a 10mm round switch. 
These switches are commonly held together by pins that are fortunately visible on these. 
First Iāll open one up. 
Aside from the shape, the functional difference between the two is that the omten uses the contact ārivetā to bridge the tabs at either end while the round switch uses the rivet spring to bridge from the tabs to the spring base plate which limits current to ~1/2A before the spring overheats. The mod is simple consisting of just cutting the contact plate in two and no longer using the spring base as a contact point. 
I guess the shears were a bit large for the job. I used a Dremel to open up the gap a bit more then sanded the edges and put it back together. Iāll remove the pieces again when I solder wires to them. 
This made the hand ache considerably as the elbow was no help at all.
Another small update
This is more unseen miniaturization work. Looks good RBD, the recovery that is. 
My wrist was bugging me so I did something a bit more fixed. These are the spacers that go between the fins. 
Theyāre a bit uneven in width but this is how they work with the fins. 
To get the spacers the right size I made up a jig with the cut out from one of the fins and a fender washer. 
Iāll put a piece of tape on the smaller disc, the spacer fits around it and when Iāve sanded through the tape the spacer will be just the same thickness as the fins (1.5mm). The fins also need some work. The center hole is just a tad small and not well centered on all of them. 
First Iāll Dremel the hole a bit in favor of center and then ream it out to a snug fit on the copper core. After that Iāll polish the flat sides. The edges will get evened up after itās assembled.
Polishing and sizing
Its good to see you back at it RBD. I love your creativity with the cutting of the fins.
Wrist is improving slowly now which is a change from the first week but still have a difficult time turning my hand with only about 45 degrees without pain vs 180 for the left. To sand Iāll have to hold the plywood and sandpaper up on edge nice I canāt turn my hand palm down. That or do it left handed. Probably both.
Iāll send you some pain killers if you like. They are working wonders for me at the moment. 
There are times when Iād like nothing better but itās manageable and tells me when Iāve gone too far. When Iām late with the ibuprofen the ache is tiresome though. Slept through the night for the first time so even that is getting better.
Yup, went too far and was late self medicating but I get OCD when Iām working so at least thereās something to show for it. Started out with lots and lots of wet sanding with 400, 600, 1500, and 2000. Both sides of the 4 discs for about 2 hrs total. 
Then I loaded the spacer rings onto a hole saw wrapped in tape and chucked into a hand drill and spun it past 220 dry, then the same wet 400, 600, 1500, and 2000. Here it is after the 600.
And again after the 2000.
The difference will be more apparent after the polishing that comes later. In any case the next thing to do was to sand them closer to size with the jig I made the other day. Here they are slipped onto the copper core. 
This next pic was taken earlier but is here to show the rings, discs, and sanding jig. 
Everything will get at least one more round of wet sanding before assembly. Next up will be reaming the discs so they fit over the core.
Reaming the discs
Rings look good
Yeah, glad your wrist is doing better, and youāre able to do a little bit!
Thanks, Iām glad itās getting better too. Just finished reaming the discs to fit. They still need truing up to the outside but hereās how they fit minus the wood collar. 
Parting is such sweet sorrow
Man, you still got the touch!
Really love your work!
I never understood and dont understand the patience you guys have. 
nice workmanship
Parting is such sweet sorrow.
Shucks. Ask anyone, Iām not patient, just OCD.
So Iām dog sitting Frances, the cattle dog and brought some things to play with while Iām there, among other things, the wood collar piece. And proceeded to cut off the plywood section with my little Vaughan mini bear saw. 
Remember the paper between the pieces of wood? This is where I comes in handy. 
After that it took only seconds to sand down to clean wood. 
I think the grey w/d sandpaper skews the white balance a bit. I went home earlier today and cut a fifth disc and fitted it as well(all still just loose parts).
And here showing more or less the depth of the reflector. 
If I use this one then all of the copper pill is in the finned area whereas with a p60 reflector part of the pill extends into the hollow under the wood. Iām not really sold on these fins, they seem too thick and chunky to me at 1.5mm thickness. Iād like to have the same mass in the same length with more surface area so on the way back this evening I stopped by the salvage yard and found some more aluminum sheet. $1.50 for both of these. Oneās 1.4mm thick and the round one is 1.25mm and about 12ā in length. 
First Iāll see how I like the 1.25mm stuff but itāll be a few days before that. Other things will happen first when your modding with ADD.
Some prep and a reflector mod
OCD aye. Iām not sure about that but anyway. 
That piece of timber just looks better with age. As far as the fins look though, mine are from memory 1.25 and I reckoned they looked thick. Must be a trick of the eyes.