Dumbbell Rack Joint Fit Coupons - Unloaded Prototypes
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Unloaded M5 insert and M6 bolt/sleeve fit gauges for rack development. CAD checked; physical fit unverified.
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Original, AI-assisted design by Isaiah Dupree. Two unloaded fit gauges for a modular dumbbell carrier project. This release contains coupons only. The full rack is an unmeasured, unqualified CAD study. No load or lifting capacity is claimed.
FILES AND ORIENTATION
Print one of each STL at 100% scale, flat base on the bed, holes upward. Editable STEP files are included. View the holed face with the unique clipped corner at bottom left; diameters increase left to right.
insert_coupon: 120 x 28 x 18 mm. Five blind holes: 6.8, 7.0, 7.2, 7.4 and 7.6 mm diameter, each 9 mm deep.
bolt_coupon: 75 x 60 x 16 mm. Row nearest the clipped edge: 6.4, 6.6 and 6.8 mm through holes. Far row: 8.0, 8.2 and 8.4 mm through holes.
The blind-hole range investigates a candidate M5 heat-set insert. M5 names the screw thread, not a universal insert outside diameter. Select an actual insert SKU and supplier drawing first. The smaller through-hole row investigates M6 clearance; the larger row investigates an unselected compression sleeve. Hardware compatibility is unverified.
STARTING PRINT STUDY
Proposed process: 0.4 mm nozzle, 0.20 mm layers, at least six walls, greater than 50% infill, solid material around inserts, properly tuned filament profile. PETG is proposed; exact filament, process and fit are unverified. No G-code is supplied. Both coupons individually fit the project's provisional V400 circular 280 mm working envelope with a 5 mm brim; review actual slicer toolpaths before printing.
Record printer, nozzle, filament grade/lot, drying, extrusion settings, specimen ID, measured holes, hardware SKU and installation results. Preserve the clipped-corner orientation in photos. Reject cracks, loose inserts and bottomed screws. Fit does not establish structural capacity.
EVIDENCE AND LIMITS
Authenticated Orion job mdl_065753e6f4e2430a produced the actual STEP/STL files and CAD render. The development audit passed 156 CAD checks, including 14 coupon export checks. An independent geometry review confirmed the 11 hole diameters, blind depth and orientation markers. The image is a CAD render, not a photograph of a print.
Physical printing, hardware fit, insertion torque, creep, strength and loaded transport have not been validated. The main carrier needs actual dumbbell measurements, selected reinforcement and restraints before those claims can be assessed. No third-party GrabCAD geometry is included.
Source, file hashes, CAD checks, licence and complete ZIP:
https://github.com/IsaiahDupree/3d-print-library/tree/main/models/dumbbell-rack-joint-fit-coupons
Printer file/history provenance audit:
https://github.com/IsaiahDupree/3d-print-library/tree/main/printer-audits/2026-10-17
Licence: CC BY-NC-SA 4.0. Attribute Isaiah Dupree, link this release and describe modifications when sharing a remix.