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ZapWizard's Leatherman Free P4 Mods

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us Offline ZapWizard

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ZapWizard's Leatherman Free P4 Mods
on: May 08, 2019, 05:32:26 PM


Howdy Folks,

I will be developing several new mods and other projects related to the Leatherman Free P4.
I make these designs because I want them for myself. However, since I use professional 3D printing on the final product, most of these will become available to purchase from my shop (Link in signature)

I will be posting progress on each project here.

Here is my list of planned projects/mods:
  • Form fit holster, similar to my Wave/Charge/Surge designs
  • Thumb tabs to make opening the tools easier
  • Bit holder to replace the Phillips and Flat-head
  • Laser-etched ruler along inside of scales

00 Offline Dutch_Tooler

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #1 on: May 08, 2019, 05:47:10 PM
That sounds very interesting Zap... especially that bit holder. Is that going to fit the LM specific flat bits?
Cheers!
Dutch_Tooler

Location: Southern Germany, most of the time
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se Offline RF52

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #2 on: May 08, 2019, 05:50:34 PM
:popcorn:

Sent fra min FRD-L09 via Tapatalk

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gb Offline Wspeed

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #3 on: May 08, 2019, 05:52:34 PM
Interesting  :popcorn:
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us Offline ZapWizard

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ZapWizard's Leatherman Free P4 Mods
Reply #4 on: May 08, 2019, 06:04:48 PM
Quote from: Dutch_Tooler on May 08, 2019, 05:47:10 PM
That sounds very interesting Zap... especially that bit holder. Is that going to fit the LM specific flat bits?
No, the plan is to make a part that replaces the two tools in the stack. I have thought about making one that fits the screw driver, but I figure Leatherman will eventually make one. I also would rather have it integrated.

Edit: I misread your question: Yes it would fit the flat bits. There isn’t room for a regular hex holder.

-------------



The first day I got my Free ($140) P4 I took it apart.

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I then used a tele-macro-lens setup to take detailed photos of each and every part.
(The contrast is intentionally very high in the shot)

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Using the images, along with measurements using calipers, I created a very detailed 3D model of tool. I tried to spare no detail on this one.
I am a product design engineer by trade, so this stuff is what I do. I also get access to amazing 3D tools such as Solid Edge and Keyshot.
The image at the top of the thread is a 3D rendering of the completed model.

-------------



This image shows the end of day #3.
The red/blue objects are my first design for the thumb-tabs (more on those later)
The green object is me mocking up the latching mechanism I plan on using on the holster. At first I thought I would have to engage with the springs on both sides of the tool, but it turned out one side works great.

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This is rev 7 of my holster design. Each revision is 3D printed on a FDM machine to test fit and work out any issues.
You may notice the P4 looks odd in the image, that is because there are four orientations on top of each other.

-------------



Here is a short history of the revision stages:
  • Rev 1: Basic form and fit 3D print to test that the spring catches will work on when only-one side of the tool. This prototype showed you need to remove the lanyard clip (Mute point now that the P4 has a belt clip instead)
  • Rev 2: Tweaked fit of catch mechanism. Tested Tek-Lok compatible hole spacing. Added supports near top to better grip the tool. Large base finger opening
  • Rev 3: Tried adding some top catches, to fit into cutouts near pliers. (didn't work well) Realized I can open the middle of the holster for a cooler look..
  • Rev 4: Added top-spring catches, allowing the tool to fit in any which way. . Having issues because there is only a blade on one side of the tool, so the other side can twist outwards, making the holster feel loose
  • Rev 5: Added two small supports to the front to hold tool in better, prevent twisting.They worked great. Added lots of side geometry to make sides as stiff as possible
  • Rev 6: Realized the top spring stops are redundant. Strengthened front tabs,].
  • Rev 7: (Currently on the 3D printer) Thickened front tabs.  tweaked catch strength to try to balance top/bottom catch force
« Last Edit: May 08, 2019, 06:12:32 PM by ZapWizard »

spam Offline comis

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #5 on: May 08, 2019, 06:12:55 PM
Wow...


 :popcorn:
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us Offline SteveC

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #6 on: May 08, 2019, 06:20:47 PM
Very cool and thanks for signing up for the fabricator membership !
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gb Offline Wspeed

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #7 on: May 08, 2019, 06:25:23 PM
Very nice designs can’t wait to see more  :popcorn:
fail to prepare prepare to fail
Merit Badges Must put something in order and provide link to the post. Join the brave and happy few, who choose a different path. Enter on the boulevard of broken dreams. Start a new thread with a photo of a modded knife or multitool with your EDC Must post a step by step pictorial of a knife or multitool modification (scale swap not included) For those who posted like a boss. Only for the 14th year Anniversary Challenge. Post a photo of any gear for thirty (30) consecutive days during the MTo anniversary month. You have one of your pictures in the 2020 calendar or in top three of the calendar poll in any month of the given year. Start a new thread and post a photo of the LM Crunch  Multitool for thirty (30) consecutive days. Start a new thread and post a photo of any gear for thirty (30) consecutive days during the MTo anniversary month. Start a new thread and post a photo of a traditional folder for thirty (30) consecutive days. Start a new thread and post a photo of the leatherman (supertool, core, hacks) for thirty (30) consecutive days. Start a new thread and post a photo of the multitool for thirty (30) consecutive days. Start a new thread with a photo showing the Swiss Army Knife   Toothpick being used in an unusual way. You have one of your pictures in the 2019 calendar or in top three of the calendar poll in any month of the given year. Participate in a challenge thread and post a photo of a SAK Cybertool (any variant), Swisschamp, Champion or Toolchest for thirty (30) consecutive days. Start a new thread demonstrating paracord knot tying Start a new thread with photos of your Buck knives in use Must start a thread with a photo of your camo SAK  Post a pic for Halloween of your pumpkin (or turnip or gourd or whatever you traditionally carve for Halloween!) being carved by any SAK, multitool, pocket or woods knife you may own!  Only available once a year Start a new thread and post a photo of the multitool for thirty (30) consecutive days. Start a new thread including a photo of shooting at least two (2) different airguns and at least one (1) photo of target (airguns)

hr Offline Vjeko Posavac

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #8 on: May 08, 2019, 10:04:41 PM
Nice!
 :tu: :popcorn:
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us Offline Poncho65

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #9 on: May 08, 2019, 11:26:53 PM
Quote from: SteveC on May 08, 2019, 06:20:47 PM
Very cool and thanks for signing up for the fabricator membership !

 :iagree: :like:

Quote from: Wspeed on May 08, 2019, 06:25:23 PM
Very nice designs can’t wait to see more  :popcorn:

Also :iagree: :like:
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au Offline aussieman

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #10 on: May 09, 2019, 07:56:51 AM
Some thoughts in order...

a)  :drool:
b)  :salute:
c)  :popcorn:
d) how possible is it to have the belt clip central? (don't like the tool carrying too low)

This is amazing though, love the pics and the insight into the process.

us Offline gerleatherberman

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #11 on: May 09, 2019, 08:03:13 AM
Seriously. I WILL be anxiously awaiting the results of the mods. :popcorn:

Thank you for all of your efforts so far, ZapWizard. :salute:
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us Offline ZapWizard

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #12 on: May 09, 2019, 02:14:34 PM
Quote from: aussieman on May 09, 2019, 07:56:51 AM
d) how possible is it to have the belt clip central? (don't like the tool carrying too low)

The belt clip holes are #2-56 drilled and tapped holes in the scales. Drill and tape your own holes to put the clip anywhere you want. Just provide some protection to prevent the shaving from getting on the magnet. Or take it apart beforehand.

spam Offline Happy Gilmore

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #13 on: May 10, 2019, 07:26:05 PM
My interest in the p2 is now directly proportional to your progress on this project. I do some design on OnShape for 3d printing projects, but your work is truly next level. Really wish I had your skill set.

Cheers,
HG

us Offline ZapWizard

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #14 on: May 10, 2019, 11:38:57 PM
Note: I am not designing for the P2 at this time, just the P4 that I own. The P2 is a bit pricey. I can't afford to purchase every single possible tool.

us Offline Douglas

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #15 on: May 11, 2019, 12:38:51 AM
I must as a question unrelated to your VERY IMPRESSIVE work here.  The Chicago screws that are used as the pivot for the tools look to be 4 mm in your photo.  Is this actually the case?  I have a project that I can't seem to get off the ground because I can't seem to find a 4 mm pivot.
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spam Offline Happy Gilmore

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #16 on: May 11, 2019, 01:00:54 AM
Quote from: ZapWizard on May 10, 2019, 11:38:57 PM
Note: I am not designing for the P2 at this time, just the P4 that I own. The P2 is a bit pricey. I can't afford to purchase every single possible tool.

I believe the p2 has the same space and frame so it should accept any bit exchanger u design for it as well. That is what I was referring to.

00 Offline Sam Lim

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #17 on: May 11, 2019, 02:01:35 AM
Quote from: Douglas on May 11, 2019, 12:38:51 AM
I must as a question unrelated to your VERY IMPRESSIVE work here.  The Chicago screws that are used as the pivot for the tools look to be 4 mm in your photo.  Is this actually the case?  I have a project that I can't seem to get off the ground because I can't seem to find a 4 mm pivot.

The screw post are smaller than 3mm. It's the same size LM uses for the rivets on the juice series. 4mm? Spirit?  :like:
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us Offline Douglas

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #18 on: May 11, 2019, 02:28:24 AM
Quote from: Sam Lim on May 11, 2019, 02:01:35 AM
The screw post are smaller than 3mm. It's the same size LM uses for the rivets on the juice series. 4mm? Spirit?  :like:

 :tu: YOU guessed IT. :salute:
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us Offline tommywp

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #19 on: May 11, 2019, 02:29:40 AM
Smurf yeah! Very excited about this thread!!

 :multi:

00 Offline Sam Lim

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #20 on: May 11, 2019, 04:17:02 AM
Quote from: Douglas on May 11, 2019, 02:28:24 AM
:tu: YOU guessed IT. :salute:

 :D I also have problem sourcing for that. Buying them standalone will be difficult. At least for where I am. I have realise alot of non mainstream brands, those made in China uses metric size pivots. Very common are 5mm and 4mm. And they are often cheaper than buying just the screws. Strip them for their parts.

Sorry for hijacking the thread!  :salute:
Merit Badges Must post a step by step pictorial of a knife or MT Mod, done by you that includes changing the main chassis of the tool in a significant way. By machining, welding or cutting original design to accept new tool loads. Requests will be reviewed.

au Offline munecito

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #21 on: May 11, 2019, 04:35:05 AM
 :hatsoff: :hatsoff: :hatsoff:

us Offline ZapWizard

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #22 on: May 11, 2019, 05:04:28 AM
Quote from: Douglas on May 11, 2019, 12:38:51 AM
The Chicago screws that are used as the pivot for the tools look to be 4 mm in your photo.  Is this actually the case?

It was quite hard to determine some of the parts, as Leatherman uses a mix of Imperial and Metric measurements. I used thread guages and calipers to determine the screw sizes.
The chicago screw tool pivots near the pliers are #6-40 threaded posts, with a diameter of 3/16" (4.76mm), and 5/8" (15.84mm).



-------------------------------------------------

The chicago screws at the blade end are #2-56. 3.1mm diameter, and 16.7mm long.

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Quote from: Happy Gilmore on May 11, 2019, 01:00:54 AM
I believe the p2 has the same space and frame so it should accept any bit exchanger u design for it as well. That is what I was referring to.
Gotcha, yes that should be the same.

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Here is an early image of the design for a bit holder.
It would be made from 3d printed steel. It would keep the can opener (as long as prototypes show it has a strong enough hold on the tool) It also would gain a 1/4" hex opening were the opener is.
The bit would be held in by a magnet.

Fitting the flat leatherman bit into the space left in the P4 was tricky. What I ended up having to do was offset the bit holder by five degrees. But that would make it off axis when open. I then realized I could offset the open lock by the same angle, and make it straight when open.

This one will require quite a bit of time to develop as the 3D printed steel can shrink sort of like a casting, and I also have to get the locking mechanism to work just right.

-------------------------------------------------



This is the final rendering for the P4 holster with normal belt loop. I am still working out a few other attachment loops, clips and methods to suite the various requests I have received in the past.

gb Offline Wspeed

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #23 on: May 11, 2019, 12:34:51 PM
 :dd: :like: :like:
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tr Offline ddogu

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #24 on: May 11, 2019, 01:39:25 PM
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00 Offline Dutch_Tooler

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #25 on: May 11, 2019, 01:53:22 PM
 :iagree: :iagree:

 :like:  :drool:  :popcorn:
Cheers!
Dutch_Tooler

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gb Offline Jaypeebee

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #26 on: May 11, 2019, 03:08:27 PM
Excellent work ZapWizard  :tu:
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au Offline ReamerPunch

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #27 on: May 11, 2019, 06:06:36 PM
Awesome work! :like:
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gb Offline Wspeed

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #28 on: May 11, 2019, 06:08:38 PM
That flat bit driver looks excellent  :dd: :like: :like:
fail to prepare prepare to fail
Merit Badges Must put something in order and provide link to the post. Join the brave and happy few, who choose a different path. Enter on the boulevard of broken dreams. Start a new thread with a photo of a modded knife or multitool with your EDC Must post a step by step pictorial of a knife or multitool modification (scale swap not included) For those who posted like a boss. Only for the 14th year Anniversary Challenge. Post a photo of any gear for thirty (30) consecutive days during the MTo anniversary month. You have one of your pictures in the 2020 calendar or in top three of the calendar poll in any month of the given year. Start a new thread and post a photo of the LM Crunch  Multitool for thirty (30) consecutive days. Start a new thread and post a photo of any gear for thirty (30) consecutive days during the MTo anniversary month. Start a new thread and post a photo of a traditional folder for thirty (30) consecutive days. Start a new thread and post a photo of the leatherman (supertool, core, hacks) for thirty (30) consecutive days. Start a new thread and post a photo of the multitool for thirty (30) consecutive days. Start a new thread with a photo showing the Swiss Army Knife   Toothpick being used in an unusual way. You have one of your pictures in the 2019 calendar or in top three of the calendar poll in any month of the given year. Participate in a challenge thread and post a photo of a SAK Cybertool (any variant), Swisschamp, Champion or Toolchest for thirty (30) consecutive days. Start a new thread demonstrating paracord knot tying Start a new thread with photos of your Buck knives in use Must start a thread with a photo of your camo SAK  Post a pic for Halloween of your pumpkin (or turnip or gourd or whatever you traditionally carve for Halloween!) being carved by any SAK, multitool, pocket or woods knife you may own!  Only available once a year Start a new thread and post a photo of the multitool for thirty (30) consecutive days. Start a new thread including a photo of shooting at least two (2) different airguns and at least one (1) photo of target (airguns)

spam Offline Happy Gilmore

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Re: ZapWizard's Leatherman Free P4 Mods
Reply #29 on: May 11, 2019, 10:22:22 PM
A bit driver...can opener and 1/4 inch driver....we are not worthy, not worthy!

 :hatsoff: :hatsoff: :hatsoff: :drool: :drool: :drool:

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