Quoted from pete_d:I did mention this in my earlier post, but I understand not everyone wants to read through the longer ones.
The 3D part I designed includes a hole, through which a hex key wrench (allen key) can be inserted. I'm replacing the existing crosspoint/Philips screws with hex-drive screws.
I was hoping to find hex head screws in that size (5-44 4-48). That way, a regular open-end wrench could be used to secure the fastener. I think for this application, one could even 3D print a suitable wrench, since the screw doesn't really need a lot of torque on it.
But none of the usual hardware suppliers have a 5-44 4-48 hex head screw. They do have options for the hex drive screws though.
The through-hole for the hex wrench prints perfectly without supports and doesn't compromise the basic strength of the mount, so given that I was going to be replacing the screws anyway, I think it's a fine solution.
In theory, you could still use the original screws, if you can find a very small screwdriver that would fit through the hole. When I looked (again, at my usual suppliers), I found screwdrivers small enough to fit in terms of diameter, but they are still all too long. The shortest I found was over 4", which is still too long to squeeze into the space inside the speaker hole where it'd need to go. A screwdriver would have to be no longer than 3" to fit.
In terms of trying to do it without the through-hole, I'm not sure even the smallest 90-degree driver would work. The thinnest I've seen still need almost 1/2" of clearance, and there's barely 1/4" between the screw head and the mounting boss.
That said, I did design the part with what I think are sufficiently large gaps around those holes to provide options for a larger wrench or driver to at least be able to rotate around with the screw head, in case other people have an easier time finding specific alternatives than I did.
If I'm following on the issue with the LCD plate screw access - I don't see any reason that needs screwed into the speaker mount. Why not just design the plate with channels to slide over the screws (screw the LCD just into the metal housing, speaker mount just goes over).
