Patent ID: 8261424

Claim:
A method of manufacturing a spring plunger comprising: providing a press having a tool surface including an inclined sidewall defining a first recess, wherein said first recess is a substantially conical recess, and said inclined sidewall has an angle of inclination in a range of about 30 degrees to about 60 degrees from the horizontal; providing a spring plunger body configured as a generally hollow cylinder having a longitudinal axis and including a second recess, a proximal opening to said second recess, and a chamfered proximal end each coaxially disposed about said longitudinal axis; inserting a distally-disposed coil spring and a proximally-disposed plunger into said second recess through said proximal opening to form an assembly; positioning said assembly for contact by said press; operating said press to contact said inclined sidewall against said chamfered proximal end of said assembly, wherein said chamfered proximal end is directed by said inclined sidewall at least partially across said second recess toward said longitudinal axis so as to depressibly capture said plunger within said spring plunger body; and removing said assembly with the depressibly captured plunger from said press; wherein said spring plunger body is provided by design with an actual outside diameter which is about 0.001 inch to about 0.002 inch larger than an indicated nominal outside diameter of the spring plunger body.