Turn Signal Stalk Repair?

[usury]

I also made a FreeCAD (v0.20.2) model of the cancellation tab. I didn't see one in the *.stl section of Carpokes. Just ask and I'll send the file.

Cancellation Tab

Cancellation Tab 01-COLLAGE.jpg (128.87 KiB) Viewed 1718 times

[Zirconocene]

@usury : I'm a little out of practice but I have a resin printer and can try to print these parts. I don't know that they would stand up to actual use, but it might be a reasonable test for 3D printing. If you can send me the .stl files of anything that is not in the 3D section here, I'll see about getting it printed.

Cheers

[usury]

@Zirconocene , when I get to my computer later today where the file lives (on phone now), I'll send you the *.stl

I imagine a resin printer could print this standing on the square flat end of the larger complicated part. I also imagine bed adhesion vs UV print screen adhesion will be a problem as the wider nose of the part is formed.

[notny41]

Did you ever get this fixed? If you need, I have a lever cluster that I could ship out to you.

[Tom]

@Zirconocene , when I get to my computer later today where the file lives (on phone now), I'll send you the *.stl

I imagine a resin printer could print this standing on the square flat end of the larger complicated part. I also imagine bed adhesion vs UV print screen adhesion will be a problem as the wider nose of the part is formed.

Did you end up posting this in the .stl section here on carpokes? No pressure, but it would be a great addition to the library if so inclined. I think you can upload stl's yourself in that sub-section, but if you need any help just let me know.

[usury]

Did you ever get this fixed? If you need, I have a lever cluster that I could ship out to you.

Just yesterday I made a few more tweaks and printed a few more prototypes. The CAD is done and the model works™, but it's tricky to print and have the tolerances come out right.

There are places in the model, like the six spring pockets, that come one extrusion-width from poking into the feature behind them.

I've identified those places and made changes to various pocket depths in the model to leave more material thickness and also not adversely effect functionality.

I've also tried to eliminate the need for support as much as possible. Got it down to only three critical areas.

It's a detailed print for a filament printer. I'm close to releasing the STL here on Carpokes. (Quite possibly the 3MF since it will contain usable print settings.)

The prototypes that work the best I've printed with a 0.4mm nozzle, 0.1mm layer height, and 0.3mm extrusion width for perimeters and places with solid infill.

PSX_20231031_085329.jpg (271.79 KiB) Viewed 1516 times

[usury]

Did you end up posting this in the .stl section here on carpokes? No pressure, but it would be a great addition to the library if so inclined. I think you can upload stl's yourself in that sub-section, but if you need any help just let me know.

I got sidelined from finishing this about a month ago, busy with life happening and all that. I'm on it again this week.

I'm definitely gonna release this on Carpokes. Earlier you had mentioned making a shout-out in the newsletter about this part... I'd totally dig that.

I plan to make a write up about disassembly, cleaning, and reassembly. I have a ton of photos.

For example, I went with M4x0.70 x8mm countersunk machine screws instead of other options because there is enough plastic surrounding the rivet holes in the housing body to thread with a tap. It makes a strong positive attachment of the top metal plate that can survive multiple removals (which has been useful for prototyping this part).

This is the Prototype Post where I've documented much of the process. (I couldn't figure out what happened to the other things I remember posting when I scrolled back in this current thread. Ohhh... They're in a different thread.)

[Tom]

Did you end up posting this in the .stl section here on carpokes? No pressure, but it would be a great addition to the library if so inclined. I think you can upload stl's yourself in that sub-section, but if you need any help just let me know.

I got sidelined from finishing this about a month ago, busy with life happening and all that. I'm on it again this week.

I'm definitely gonna release this on Carpokes. Earlier you had mentioned making a shout-out in the newsletter about this part... I'd totally dig that.

I plan to make a write up about disassembly, cleaning, and reassembly. I have a ton of photos.

For example, I went with M4x0.70 x8mm countersunk machine screws instead of other options because there is enough plastic surrounding the rivet holes in the housing body to thread with a tap. It makes a strong positive attachment of the top metal plate that can survive multiple removals (which has been useful for prototyping this part).

Awesome! I've been sending out the email newsletter every Friday lately, so will include it in the then-next newsletter whenever you post it.

For threads, I am hopelessly addicted to brass heat-set inserts from McMaster. For something you assemble and forget like this part, heated inserts are probably overkill, but on things like my license plate mounts, they are worth their weight in gold. Nut pockets, Helicoils, and print-in-place nuts are also options, but I'll resist the urge to derail your post with my obsession on threads in 3D printed parts.

https://www.mcmaster.com/94180a351/

[eduard122]

i dont know sorry!