Quoted from JodyG:The big problem with this ramp, which I did not realize until discussing this with Freeplay40 is the fact that this is actually an injection molded ramp with brackets molded into it. Could this be vacuum formed? Probably. But with some caveats. The mounting brackets would have to be some kind of secondary assemblies. Possibly stainless brackets riveted to the ramp, or maybe even some brackets made of the same ramp material. Since they only hold micro switches, and are not used for mounting, there is some leeway to work with as far as that goes. Another idea would be to make those mounting flaps part of the actual lip on the top of the ramp, and then add a spacer of some sort between the switch and the mounting flap, so the switch still contacts the ball at the right place. This option seems to be the most realistic.
The second area of concern is where the 3 lanes split at the center tray. Those spots would probably need to have a special plug made for use during forming, because they will tend to thin out quite a bit when you stretch plastic over them. They are protected by posts, but I would still like to see that area as beefy as possible.
I am still willing to look into this later this year, once I get caught up on current projects.
Dont put the switch brackets in at all.
Use MRS switches there instead.
They are better and just stick on with VHB tape.
