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ZapWizard's Leatherman Free P4 Mods 19464

Full Member Posts: 111
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
No Life Club Posts: 3,843
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
No Life Club Posts: 3,840
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

Just Bananas Posts: 70,951
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #3 on: May 08, 2019, 05:52:34 PM »
Interesting  :popcorn:

fail to prepare prepare to fail
Full Member Posts: 111
ZapWizard's Leatherman Free P4 Mods
« Reply #4 on: May 08, 2019, 06:04:48 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.

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



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)

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



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.

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



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 »

Absolutely No Life Club Posts: 6,569
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #5 on: May 08, 2019, 06:12:55 PM »
Wow...


 :popcorn:

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Global Moderator Abandon All Hope Ye Who Enter Here... Posts: 45,574
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 !
Just Bananas Posts: 70,951
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
Sr. Member Posts: 282
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #8 on: May 08, 2019, 10:04:41 PM »
Nice!
 :tu: :popcorn:
Global Moderator He Who Has The Most Nuts, Wins! Posts: 59,000
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #9 on: May 08, 2019, 11:26:53 PM »
Very cool and thanks for signing up for the fabricator membership !

 :iagree: :like:

Very nice designs can’t wait to see more  :popcorn:

Also :iagree: :like:
Jr. Member Posts: 57
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.
Zombie Apprentice Posts: 10,549 Man of Multiple MultiTool Manufacturers
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:

Pontificating particularly pious positions pertaining to polymorphic paraphernalia. G-Man.
Full Member Posts: 111
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #12 on: May 09, 2019, 02:14:34 PM »
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.
Hero Member Posts: 800
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
Full Member Posts: 111
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.
No Life Club Posts: 4,050
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.

"LOGIC!  My God, the man's talking about logic!  We're talking about Universal Armageddon!"
Dr.  McCoy

MTo...The BEST place on Earth!
Hero Member Posts: 800
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #16 on: May 11, 2019, 01:00:54 AM »
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.
No Life Club Posts: 2,113
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #17 on: May 11, 2019, 02:01:35 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:
No Life Club Posts: 4,050
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #18 on: May 11, 2019, 02:28:24 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:

"LOGIC!  My God, the man's talking about logic!  We're talking about Universal Armageddon!"
Dr.  McCoy

MTo...The BEST place on Earth!
Sr. Member Posts: 470
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:
No Life Club Posts: 2,113
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #20 on: May 11, 2019, 04:17:02 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:
Full Member Posts: 152
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #21 on: May 11, 2019, 04:35:05 AM »
 :hatsoff: :hatsoff: :hatsoff:
Full Member Posts: 111
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #22 on: May 11, 2019, 05:04:28 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.

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

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.

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



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.
Just Bananas Posts: 70,951
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #23 on: May 11, 2019, 12:34:51 PM »
 :dd: :like: :like:

fail to prepare prepare to fail
No Life Club Posts: 1,309
No Life Club Posts: 3,843
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

Location: Southern Germany, most of the time
No Life Club Posts: 1,279
Re: ZapWizard's Leatherman Free P4 Mods
« Reply #26 on: May 11, 2019, 03:08:27 PM »
Excellent work ZapWizard  :tu:
Thread Killer 2017 Absolutely No Life Club Posts: 6,168 Born to multitask.
Just Bananas Posts: 70,951
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
Hero Member Posts: 800
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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