Dashboard binnacle repairs

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Re: Dashboard binnacle repairs

Postby CJH » 10 Jul 2018, 17:48

CJH wrote:How about I finish off the parts for the last corner, then do a post showing all the different parts, and I'll try to give them sensible names so that you can specify exactly which piece(s) you need.


This might take a little longer than I thought, because a couple of the corners are a few degrees off a right-angle. I'll make versions for those corners, but I need to get my naming convention right or it'll all get too confusing.
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Re: Dashboard binnacle repairs

Postby CJH » 12 Jul 2018, 10:22

My longer self-tappers arrived yesterday, so I was able to fit the binnacle clamps. The curved profile of the original binnacle mounts means that the clamps have to bend slightly when the screws are done up. This means that they apply pressure along the whole length of the binnacle mount, so they make good use of the unbroken bits of the mount.

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Image

I'm nearly organised with all the other bits - just need to make up some diagrams now.
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Re: Dashboard binnacle repairs

Postby Smcknighty » 12 Jul 2018, 13:39

Got my side bits, fit looks good, thanks for doing those


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Re: Dashboard binnacle repairs

Postby CovKid » 12 Jul 2018, 21:57

Long term the answer would be a brand new reproduction of the entire dash pod but the perspex screens would make this incredibly difficult to do. The biggest cause of failure of the plastic is the heat it gets exposed to over the years, plus freezing temperatures. I'd still like to have a go at making a pod from sheet ally but needs a CNC guy to make a neat job of it.
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Re: Dashboard binnacle repairs

Postby CJH » 15 Jul 2018, 08:20

CovKid wrote:Long term the answer would be a brand new reproduction of the entire dash pod but the perspex screens would make this incredibly difficult to do.


Thankfully my printer isn't big enough to print an entire binnacle, otherwise I just know I'd be tempted to start modelling one. That could be a very time-consuming process.

I realised that my binnacle clamps weren't a perfect fit in the end near the rearmost screws. I modelled the piece to fit a mounting tab that didn't have a lip on the final segment, so the final finger distorts when fitted to one that does have that lip - mine included.

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So I adjusted the model slightly so it fits nice and flat.

Image

I also realised that the material I normally print with, PLA, isn't ideal for this sort of part, since it will get very hot under the dashboard cowling and PLA will distort. ABS is the better material, but it's very difficult to print successfully since it requires much higher temperatures for the nozzle and the build plate, and it's very difficult to get good build plate adhesion to avoid the printed part lifting and warping. In fact I've never managed to get a successful print of anything in ABS.

But I persevered yesterday and I think I've found the right settings to print successfully. I had to tweak the model some more to round off the corners of the fingers (it seems to help prevent lifting), but now I can print them quite reliably.

Image

So if anyone wants these in future, I'll make them in ABS - purple only I'm afraid! (@Smcknighty - I'll send a replacement pair in ABS). The various other repair pieces will be fine in PLA.
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Re: Dashboard binnacle repairs

Postby CJH » 15 Jul 2018, 09:31

For anyone who wants to print this themselves, I've uploaded the finished binnacle clamp model to Thingiverse.
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Re: Dashboard binnacle repairs

Postby Aidan » 16 Jul 2018, 09:37

fantastic work :ok
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Re: Dashboard binnacle repairs

Postby jamesakers » 16 Jul 2018, 10:23

This is brilliant CJH! Thank you for taking the time to develop this. It's something we'll definitely all need one day.
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Re: Dashboard binnacle repairs

Postby Smcknighty » 16 Jul 2018, 14:22

Brilliant work, thank you


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