DIY Stock from a ski pole, Mark 2 My first version as pictured above had just a tiny bit of wiggle at the pic rail attachment.
So I revisited the clamping method.
After examining various off-the-shelf clamps of all sorts, I realized that my approach was wrong. The point of the clamping portion is NOT to reciprocate the shape of the picatinny rail tower. The point is to use the shape of the picatinny tower to clamp to, in order to stabilize the attached device. A subtle but important difference.
So here was my redesign:
Stability is all about the clamping surface, highlighted in red. You need to generate strong force in the direction of the arrows, so that you clamp hard against the reciprocal face on the pic rail. Since the interface is slanted, this force will both hold the clamp centered as well as pull it tight to the pic rail.
For this reason, I went with a 3 piece design. I felt the symmetrical clamps would give more stability.
To generate more clamping power than a reciprocal shape could make, what I did was slightly bevel the center block portion (blue highlights) until they are actually slightly smaller than the reciprocal face on the pic rail. The difference is only about 0.4mm--too much difference and you will crack the clamping blocks. Too little difference and you will get less clamping power.
Next, I moved the through-screws much lower down, so that they are clamping as closely to the red surface as possible. They are low enough that you have to position them to go in between the pic towers. See the yellow circles.
The green highlighted stub remains, also lying in between the pic towers, which prevents the clamp from translating up or down the pic rail.
Here is the set, off the 3d printer.
And mounted up. Now this was fully stable, with no wiggle, even when exerting strong torque at the far side of the stock.