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