How to split TKR side foam and join with dove-tail or butterfly?

[rocco8773]

Since we're moving to a more rigid Tracker foam, the Tracker edge pieces can no longer flex enough to be stuffed into the Tracker volume. So, a split design needs to be drawn up. The middle split will likely need some kind of joining method, like a dovetail or butterfly. It is preferable to have a mechanical join, versus epoxy, so the edge piece(s) can be removed and re-installed.

[rocco8773]

An initial prototype (see pic) would just split the original foam pieces into non-equal segments that are joined with a butterfly. Additional design work will is needed to optimize the split location so we don't have a consistent split all the way up a tracker side.

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For prototyping I designed two 3D printable jigs that can be used with a hand-held router to cut the foam pieces. The jigs are designed so you can use a #⁠8 wood screws, like 90294A199.

Item	Component	Jig	Jig STL
Socket			STL
Plug			STL

[rocco8773]

We've decided to just split the foam and epoxy it together during installation.