I just bought the girlfriend a couple Pilot "Dr. Grip" pens at Costco
for her to write with (her hands don't close very well.)  These have a
cap (the button you push on to pop the point in & out) that looks JUST
almost like what you're describing to me - This could be chromed brass
or other metal instead of stainless steel, but I think that it, + 2
springs etc. would do the job.

  The top button is 1/4" diameter, sort of a rounded top but with a flat
center, 3/32" diameter, probably at least 1" long;  I imagine it's a
"top hat" shape;  I can't disassemble this pen without wrecking it, and
risking destruction of my self from Robin, but the pens were $6 or so
for a pair.  And you can probably sell me the refills as Robin will use
'em eventually <G>

  There's some sort of brass fitting inside the hand grip that may be
good to base the electrical connection on, even?  If you hit this cap at
a slight angle, you'd have a small 'wiping' contact area & that should
work...

  Also, The local thrift stores, swap meets, flea markets, etc. would be
good places to look for that old cordless.  Or another similar beastie.

  Mark, mwillis@nwlink.com

Lewis H. Cobb wrote:
>
> Ok, I know this is way off topic on first glance, but the project involves
> a PIC in a hand-held instrument so I figured it kind-of applies here.
>
> I'm designing a small hand-held instrument that is going to be
> re-chargable.  Rather than spending a bzillion dollars on an industrial
> design I have found a suitable off the shelf enclosure that the
> manufacturer will modify at a small cost.  There will be two "contact" pads
> on the unit that are about .2" (5mm) diameter.  I have been looking around
> for spring loaded pins that I can use to design into the mating
> charger-holder unit but all I can find are the test point probes that are
> used in the bed-of-nails testing jigs that are used in production and these
> are far too small.
>
> Years ago I remember seeing exactly what I am looking for in the holder of
> a cordless phone.  The pins were stainless and 0.250" diameter, tapering to
> a reasonable point, and sping loaded.  That phone can be found nowhere at
> this point and web searches have been fruitless.
>
> Can anyone pass along any suggestions on where I might go to find a
> manufacturer of these things or something similar?  I have already checked
> out the IDI (interconection devices) web site and they have battery
> contacts but again, they are more suited to smaller battery packs and not
> really what I am looking for.
>
> Thanks in advance for any help people can provide.
>
> Lewis
> cobb@zeus.ee.unb.ca