3D printing parts

[HPmuirt]

Hi, I’m interested to see that you have done designs for the headlight washer nozzles. If you are successful in producing some you can certainly count me as a customer. Keep us updated please.

The washer jets are an interesting one as I have no idea what is going on inside, such as how/where they restrict the water path to generate the pressure, so I have just guessed.

Also, for the first design, I did not angle the jets to the side or up, so once I am happy that the external dimensions work and the jets spray a nice pattern, then I will look at the direction of spray.

Below is the first test print beside an OEM jet
1st Comparison.jpg

I am also thinking about whether to change the connector barb for a groove with an o-ring

Cheers n beers
Si

P.S. are any admins working on fixes for the image and emoji issues on here or has everyone moved over to using Facebook (shudders as he types that word and thinks to himself "God I loath that app - the world would be a nicer place if it had never been invented!!")

[ljh61]

Hi, I’m interested to see that you have done designs for the headlight washer nozzles. If you are successful in producing some you can certainly count me as a customer. Keep us updated please.

[HPmuirt]

I think what you printed there is pretty good as it is in terms of functionality..
What about printing a floor in the rear storage pocket area that has the edges radiused so that it makes it easier to retrieve very small objects.
I hope you understand what I mean.

Thanks (smilie face here if it was working)

Yup, I think I understand what you mean and have modelled it below.

RearSpacer_v7 (tray).PNG

My only concern here is that I have been printing all the parts upside down as that means the top surface of the part is touching the glass bed and so generates the best surface finish. To do that for this piece means that the diagonal will be printed as a an overhang, so I have played with the slicer settings until the preview shows that it never prints in free air so I will run a test

Cheers n Beers
Si

[HPmuirt]

How many orders would you need to do the front gear linkage bushes?

Hey Andy,

I can do small no.s or one-offs if the modelling isn't horrendous but as I have never played with the shifter linkages on my car, all I have to go on is the 7zap picture and I don't know which bush you mean.

I can model up and print dimensionally accurate objects, but to do that I either need to have the object in my hands or an accurate diagram with all measurements.

Assuming the bush is not subjected to heavy forces, if you can send me details, I can model it up and test print it in PLA-Carbon or PETG-Carbon so that you can see if it fits, but I assume that the final print should be in a better material, Nylon maybe - which I plan to buy in the coming weeks to have a play with. I don't plan to play with Delrin yet as it can give off formaldehyde fumes and my printer is in my office.

If it is a bush that takes a beating then I would go to a local back street machine shop and get it CNC'd in Delrin etc.

Cheers n beers
Si

[Nuvo]

I think what you printed there is pretty good as it is in terms of functionality..
What about printing a floor in the rear storage pocket area that has the edges radiused so that it makes it easier to retrieve very small objects.
I hope you understand what I mean.

[andyg plym]

How many orders would you need to do the front gear linkage bushes?

[HPmuirt]

Another update...

I have finally wired in the USB ports in the front spacer so now I can refit the console back in my car.

I also printed the rear spacer as a little pocket but in this combo it might be better to print all 4 as a single unit a remove the rear sides behind the second can and so increase the size of the rear storage pocket however that removes the flexibility. Any thoughts on this or what else could be printed?

Cheers n beers
Si

v6 USB fitted - cans.PNG

[HPmuirt]

The BMG is on my list and I have printed the petsfang but not yet fitted it as the machine is in such a sweet spot I am loathed to mess with it right now, so that will be fitted when I next do some work on it. I am also a big fan of the Voron 2 as an upgrade over the Ender 3 Pro but at this stage I am still learning so that is probably a while away yet.

My concern with printing the RS2 airbox is the fact that it sits above the turbo. I know the OEM part is also made from thermoplastic, but being moulded I would assume that it will have fewer inherent weaknesses when hot compared to a 3D printed item. Also, both halves are huge parts to print so if you then have to break the halves down into pieces then you will need to create so clever and strong mechanical joints which can then be glued for extra strength. Good luck finding one in the US to copy!

Cheers n beers
Si

[paradox11235]

I've got a fairly modified ender 3 as well, running a BMG extruder, e3dv6 hotend, SKR 1.3 board, and petsfang ducting. Plus all the printed upgrades... I've been contemplating building a Voron though, that might have a large enough build area to do something like an airbox. Might have to do two parts, but I think it's 350mm square build volume. Seems like it could be a nice part to reproduce, I imagine it would be hard to get my hands on one to model it though.

[HPmuirt]

I am using a cheap and cheerful Creality Ender 3 Pro but it is turning out prints which are as good as the Ultimakers at work which are over 10x the cost. The prints were OK straight from the box but with some careful fettling and the printing of some upgrades it is really stable now, with only the occasional bed adhesion issues which a good wash with soap then IPA usually addresses as I am using a glass bed.

The only purchased upgrades are the feeder and Capricorn bowden tube, stepper dampers plus an A2 hardened steel nozzle for the high abrasive filaments such as the CF ones. I have only just started with PLA-CF and as you said, the strength improvement is disappointing but I like the matte finish so I will probably stick with it. I also have some PET-G with CF so that is next one to try and then I want to try Nylon for low stress bushings etc. I also have some TPU.

On the RS2 airbox question, I will start with my faded recollection and then wait for an expert to correct me as it is over 8 years since I upgraded. From memory, they are identical in external dimensions except that the RS2 version has a larger intake port. Internally the RS2 version has the same air filter but it is positioned to allow more air pressure before and less after it and thus higher air flow. This has been measured - I cannot remember the difference it made but Porsche seemed to think it was worth the effort so I am not going to argue with them.

Cheers n beers
Si

[paradox11235]

What sort of printer are you using? I haven't done any functional car parts yet (although I use my 3d printed walnut blasting port adapter for FSI engines regularly). Just upgraded my hotend to print carbon filaments, they aren't really that much stronger but tend to have a very nice matte finish. I'll be printing all sorts of brackets and interior upgrades I'm sure, also blank distributor caps since I run coil on plug on my 3b.

Also forgive me, as I'm from the land of no RS2s, but what makes the RS2 air box more desirable/different from an S2 box?

[HPmuirt]

Greetings,

I have had lots of messages asking me to make fairly functional parts but until I get a wider range of materials, with Nylon being one I am looking at, I want to stick to parts which are not subjected to any forces or are critical in any way. All suggestions are welcome but let's keep them on the thread rather than PMs so that the design and material can be discussed and others with printers may already have a design.

Quick update on my designs....

I now have a bit more filament, plus some PLA with carbon fibre and PET-G with carbon fibre to test and finally the USB sockets arrived so I have been making changes to the design of the front and rear spacers for the cup holders to incorporate the legs of the USB ports - pics to follow

I therefore now have a spare set of 2 sides plus a blank front spacer (without the USB ports) as shown in pic 3 in the first post of this thread, which I would be happy to sell for someone to review.

BUT, before I start selling these, I spotted some 3D printed ones on eBay in Germany and Lithuania so I wanted to make sure that I was not treading on the toes of a forum member with these. If either of these ebayer sellers are forum contributors then I will not offer to supply the forum as I was going to charge around £20 for the 2 sides....so please let me know either way.

That said, if anyone wants the "2nd hand but never actually fitted" ones inc. the blank spacer in pic 3 for £15 plus postage please let me know as I am keen to get some feedback as to how they perform being just held with velcro as per the OEM design, as my S2 is not currently being driven.

I have also been playing with the design of the rear spacer as if you don't want to cut out the pre-prepared area for a 12V socket and don't need more USB ports then would it be better to leave it as a small triangular tray? (see pic below)

image_78493.png

Also, whilst the 4 pieces shown above are designed and printed as 4 separate pieces, if you always wanted the spacers, then would it be better to print them as one solid piece so that they cannot move in relation to each other or is the flexibility to change the combination more important, in which case should I include locking pieces in the design?

My next design is the front headlight washer jets (part no. 893 807 185). Below is my first design which I will print in the next few days and see how far out I am. I have designed it with two different connectors as it needs to be snug but not so tight it breaks....

Jet_v1-Sphere.PNG Jet_v1-Cone.PNG

Cheers n beers
Si

[HPmuirt]

Too big a file for the picture. Make it smaller ie fewer kB

Tried jpg, png and bmp all less than 100Kb (which is way smaller than the images I posted earlier in this thread and still no joy. I have also tried on other threads and starting a new thread in case it was an issue with this specific thread bust still the error message....I guess it is payback for abandoning the forum for so long

Greg/David/Andy ?

Tears 4 fears
Si

[HPmuirt]

I have a centre gauge holder that looks similar to the picture you posted if you want to copy it?

Thanks Sal

The one above was drawn by me without reference to much so I guessed at the size of the slots vs material around and used an old cheap boost gauge to estimate the size and depth of the gauge and bezel holes etc. so once I get some more raw materials I might well pm you for a look at yours.

Cheers n
Si

[4WDrifter]

P.S. Why do I get the following error when trying to add an image to a new post....

"Upload failed due to failure writing temporary file."

Cheers n tears
Si

Too big a file for the picture. Make it smaller ie fewer kB