I'm building my pack right now using norman's plans. I'm on the crank generator/gear box right now, all of my plywood is cut to size, but then I realized that the PVC I have is 1 1/4. (I measured the diameter myself, I don't know how they get 1 1/4, it's more like 1 5/8).
Of course, what I'm doing is trying to build as much of my pack as possible without spending money (PVC left over from a friends project). So I'm wondering what I should do. Should I make the space between the upper and bottom portions wider, or should I go out/wait for some thinner PVC?
(main concern: I stay with what I got, make that space wider, and then find out that the hose doesn't go into the PVC right, or there isn't enough space for the ‘warning’ stick, or crank knob doesn't fit. etc…)

Easy

PVC is measured using the Inner Diameter.

Thank you captain obvious…..but i'm still wondering whether or not I'm gunna mess up my box if I try to fit it to 1 1/4.

easy

it's supposed to be 1' in diameter, but I have 1 1/4. I want to know if it's gunna mess up my measurements if I use 1 1/4 diameter PVC.

easy

I used 1-1/4“ PVC, but then again… my box was made to fit the 1-1/4” PVC.

were you using norm's plans?

Assuming that you're using my latest Y2K, June 2001 version drawings. I have the height of the opening at 1-3/8“, that being the ”outside“ diameter of the PVC tubing. Now, you may want to saw off & sand the top and bottom part of the mid section opening so that you can squeeze the PVC tubing in there or you could try finding smaller tubing that will fit in there. The plumbing section of HomeDepot has/sells short pvs type tubings that are about 12” L for a reasonable price. Check also in the section that sells vacuum cleaners/shopvac type accessories, you may find 1“ tubing in black plastic. Another method you may tried is to sand down the top and bottom of your pvc such a way that you could push it into the Crank Box/Gearbox canal ”C", keeping in mind that the top of the tube will have a rectangular strip hidding any sanding scars.