I'm going to assume that you have access to the proper tools for this project, this is not really a tutorial as much as it's just to help you locate the accurate metal stock.
I'll be offering up some measurements that I know for a fact are screen accurate, any measurements that I cannot confirm will be marked with an asterisk (*).
So here goes...
Beam Line & Filler Tube
They are cut from 1.25" (1-1/4) diameter aluminum tubes
They each measure 3.875" (3-7/8) tall.
This is the metal stock that you'll need
http://www.speedymetals.com/pc-4571-837 ... minum.aspx
You'll want to order them cut to 3-3/4" lengths and you'll have to weld on 1/8" thick lids with a 1.1875" (1-3/16) diameter.
These will then need to be welded to 1.5" (1-1/2) x 1.5" squares (these were not perfect squares on the screen used packs).
The squares are 0.125" (1/8) thick.
The EDA disks are cut from 1.1875" rods.
http://www.speedymetals.com/pc-2447-836 ... ruded.aspx
They are approximately 0.25" (1/4)* tall (they were not cut perfectly even).
The HGA's tube measures:
A: 2.5" (2-1/2) Outer Diameter
B: 2.25" (2-1/4) Inner Diameter
B: 0.125" (1/8) Wall
It is cut to 2.375" (2-3/8) long.
The lid for the HGA has a 2.375" (2-3/8) Diameter and is 0.125" (1/8) thick.
Here is the correct stock
http://www.speedymetals.com/pc-4596-837 ... minum.aspx
The outer tube is made from the same stock as the HGA and the inner rod is made from the same stock as the Beam Line & Filler Tubes. Stefan's plans should be a fair reference for the lengths and angles of the Booster Tube.
The inner plate is 0.125" (1/8) thick and has a diameter of 2.25" (2-1/4).
The N-Filter is made from 3" OD "thin wall" tube.
A: 3" OD
B: 2.870" ID
C: 0.065" Wall
It should be cut to 3.5" (3-1/2) Tall and has a 3" diameter lid which is 0.125" (1/8) thick.
Here is the correct stock
http://www.speedymetals.com/pc-4617-837 ... minum.aspx
A: 1.25" (1-1/4) OD
B: 1.0" (1) ID
C: .125" (1/8) Wall (Thick Wall)
The total height of the PPD is approximately 3.1875" (3-3/16)*.
This part gets filled with resin and then chopped at a 135 (or 45) degree angle.
The Vacuum Tube is made from the same 1.25" OD Tubing as the PPD.
It is 2.5" (2-1/2)* tall and is welded to a flat aluminum disk.
The disk is 0.125" (1/8) thick and has a diameter of 2.25" (2-1/4).
A: 1.5" (1-1/2) OD*
B: 1.370" ID*
C: .065" Wall*
The Injector tubes should be cut to 6.375" (6-3/8)
The lid is 0.125" (1/8) thick and has a 1.4375" (1-7/16)* Diameter
The tubes are welded to a 0.125" (1/8) thick plate which is approximately 3.25" (3-1/4) x 1.875" (1-7/8)
This is the stock that I'm assuming was used
http://www.speedymetals.com/pc-4575-837 ... minum.aspx
The Rear Handle is made from "Thin Wall" Tubing
A: 1.25" (1-1/4) OD
B: 1.01" (1-1/10) ID
C: 0.12" (3/25) Wall
From the top of the handle where it meets the gun body (at the weld line) it measures 8.5" (8-1/2).
http://www.speedymetals.com/pc-4573-837 ... minum.aspx
In GB2 they used angles with the dimensions:
The pieces were cut to 1" wide as seen below.
In GB1 they were all cut to 2" wide which does not fit well on the bottom of the cyclotron.
My recommendation is to get them all cut to 1.5" Wide as it gives more room for error while installing the rivets and still fits well in the cyclotron area.
I couldn't find the correct stock at Speedy Metals but if you want to order everything from the same place then this is a good replacement.
http://www.speedymetals.com/pc-2197-834 ... ruded.aspx
Like my previous posts state I bought all the metal parts I needed for fairly cheap. So I was going to print out the template and take it to a machinist to have all the caps cut out for brazing. Well I started digging around online and found a company that sell the caps for each item. And figured I would post the links to each. So here you go.
http://handrail-fittings.sharpeproducts ... resortid=0
HGA 2.375 disk 1/8 thick Item # 9229
You would have to use the same size for the booster plug and grind it or file it because the next size down is 2 inches even which would be too small. You need one for HGA cap and 1 for booster plug. price is $2.99 a piece
Filler tubes/beam lines. 1.1875 1/8th thick. Item # 9206
This is 1.25 so again minor filing or grinding to make fit. You need 2 Price is $1.20 each
Injecter tubes. 1.4375 disk 1/8th thick Item Item # 9212
this is 1.5 inches so again you would have to grind or file down very little to have correct size. You need 2. Price is $1.28 a piece.
N-filter 3.0 disk. 1/8 thick Item # 9244 You need 1. Price $5.37 each
Now for the plates that you attach the tubing to you need to go to a diffrent web site. This is the link.
https://www.metalbytheinch.com/t0/c135/ ... sheet.html
For the squares for the filler tubes/beam line you need to select .125 fot thickness, they do not go by 1/8th. Than you pick 1 and 1 1/2 by 1 1/2. Like VinC said the ones on the screen used pack are not an even square so you can play with that if you want. You will need 2. Price is $ 0.53 a piece.
For the rectangle that the injecter tubes go on you need .125 width and it will be cut to 3 1/4 by 1 7/8. You only need one.
Price for these are $0.82
They are also expensive with shipping it is $16.01 to NH. thats 4 6 squares and 3 rectangles. It may be cheaper to go to HD and find some 1/8 thick 2 x 36 inch flat bar http://www.homedepot.com/h_d1/N-5yc1v/R ... ogId=10053 .
Again Thank You VinC for getting all the tubing and 1/8 cap and plate info. I hope this helps you guys.
For the plate that the injecter tubes attach to you need a 3 1/4