Help cutting an O ring grove

[TomG]

Since you are not using them for sealing, I would suggest choosing the next smaller O-Ring and size the inside diameter of the groove so you end up with the desired amount of O-Ring sticking out. Just remember to use the actual size of the O-Ring in your calculations because they run larger than nominal. McMaster Carr lists the exact sizes. You'll also want to start large and work your way down to get the right feel on the fit. These things are difficult to calculate. I use O-Rings all the time for things other than sealing when I design. The orange colored silicone one's that McMaster sells are quite durable.

Tom