I am prototyping a nested waveguide made of four cylindrical sections. Each piece is turned on a lathe from Delrin (acetal) rod. Each piece fits inside the next larger one.
There are no moving parts. It is an antenna.
My question is: how much larger must the ID of a cylinder be, than the OD of the one which fits inside it?
In my drawing, I have indicated that they be 10 thousandths of an inch larger, but I do not know if this is correct.
I would like to be able to disassemble the cylinders during experiment, to take measurements, and then put them back together.
Each cylinder is to be electroformed with nickel on the outside, so the thickness of the metal layer will also be taken into account.
Here is an updated drawing with tolerances added and revised diameters.