pic: Floating Zip Tie Chain Tensioner

[NickE]

Originally Posted by dtengineering

I can see why you would want two different sized grooves for the chain to accommodate both #25 and #35 chain, but do you need the different sized grooves for the zip ties, too?

I ask only because it would seem to save a few manufacturing steps to put only a single groove in for each zip tie.

In a similar vein, would it, perhaps, be easier to drill the holes ALL the way through the tensioner? That way you would only need to do two drilling operations rather than four.

I agree that the 2 grooves for zipties seems unneccesary, and that the holes could go all the way through.

Another thing to consider:
If you were to make 2 different models for two different sizes of chain, it would simplify your design immensely.
I doubt many teams will be switching their tensioners between different sizes of chain very often.
Just because there is demand for more than one chain size, doesn't mean you need to incorporate all sizes into one product

Honestly, I liked your original design better. I think the most recent one you posted looks too complicated and time-consuming to machine.