Using your 3D Printer to repair your vehicle

[Firebrick43]

So my GMT800 suburban like many other of its brethren has broken the clip where the rear of the switch panel attaches. It also broke the front post where it bolts to the door panel from underneath. I "believe" that only the higher optioned LT with the large switch array had the front bolt. The previous owner had duck taped the switch panel in place with all its glorious tackiness.

3D printed parts present a lot of opportunity to save older interior parts.

There are clips similar to the one i designed here for the rear on eBay. There was one model on printables but it fitted very poorly into the pocket, so I designed a new one that fits almost perfectly in my door after 11 revisions. Print solid for strength and use PETG or ABS/ASA for heat resistance. It likely would stay in place with the switch panel in place but to keep it in place with it out I lightly glued it in with 30 min epoxy in the arm rest pocket.

I also made a piece that fit over the front post to strengthen it after glueing it back on as the walls are thin. Its a complex shape as well but was easier to measure and see fit up so it went much faster.



Used a well fitting drill bit as an alignment pin to glue the original post back on with ABS cement (scigrip 16)

Then epoxied the 3D printed piece over it, after it tacked up I turned it onto its side and added epoxy fillets to the back side

Solid repaired switch panel back in place.

GMT800 Silverado / Tahoe / Suburban / Yukon Door handle repair clip (1999-2007) by Firebrick43 | Download free STL model | Printables.com

These clips are for repairing the plastic clip that is part of the door handle/armrest. | Download free 3D printable STL models

www.printables.com

GMT800 LT Silverado / Tahoe / Suburban / Yukon Door Switch post repair (1999-2007) by Firebrick43 | Download free STL model | Printables.com

This part helps repair the front post on higher optioned LT models that can break if the rear clip does. | Download free 3D printable STL models

www.printables.com

 

[jonshonda]

Just designing a one off prototype clip makes you appreciate all the work that goes into designing an entire vehicle full of clips. Especially considering up until recently 3D prototyping wasn't a thing.

 

[JSGAuto]

That's nice. I may borrow that when I get to my interior work. ('02 pickup)

 

[75gmck25]

If you have the skill, tools and time, 3D printing can be really useful.

My Mechanical Engineer son worked for a company where he designed 3D printers, include one that could print metal. I believe the primary market for the metal printer was for companies doing one-off prototypes where they were trying multiple designs for brackets and other relatively small parts. Metal printing takes a couple of days for the entire process, but it is still faster than contracting for a detailed one-off part designed and made by milling or casting.

During a home repair I dropped a decorative (colonial style) metal hinge for a shutter, didn't notice it, and it got lost in the dirt. My son used their software to do a 3D scan of one of the hinges I still had, and then printed a replacement decorative metal hinge for me. I expect this would have been an expensive custom job if I had paid for it, but he just chalked it up to training on how to use their software and machines.

 

[supersaiyan93]

The windshield cowls on early Porsche Boxsters and 996 911's had flimsy mounts that get brittle and break off. A new one is over $200. Someone on Thingaverse created a 3d wedge that uses the OEM bolts to hold the cowl on. Got them printed for about $15, and now I'm good to go.

 

[1redTA]

I’ve used my 3d printer to recreate no longer sold parts for my 81 MasterCraft, some guage pods for my 08 Sierra and soon some for my 85 RX7 im sure. I’d love to get a 3d scanner that didn’t cost a fortune

 

[BearsFan315]

done a ton here
since a mechanical engineer by trade 20+ years mainly in design & R&D i have designed clips, holders, prototypes for fabrication, etc... for my daily driver, things in the garage, my 1929, and many other things. also print clips for my neighbors canopy tent, do those in batches, he breaks them and i print another batch also designed a hold down clap for a neighbors access panel.
also just got a new to me 3d printer for doing larger things, got a lot of hours on my old reliable 3d printer.
I do put a lot of my designs up on Thingiverse for others.

 

[Daedalus]

I expect this would have been an expensive custom job if I had paid for it, but he just chalked it up to training on how to use their software and machines.

At my co the guys with the least amount of hair still call them G-jobs, but the rest of us refer to them as "calibration prints" to "help make sure the equipment is still meeting expected performance and tolerances".

I've designed hundreds of 3D-printed shop aids in the past few years, to help with various aspects of one-off productions. Mostly just 3rd-hand fixturing, bonding/assembly jigs, etc, but also as check/clearance gauges. I just modeled and sent 2 jobs out today, 1 for a custom spring clip designed to compress 2 parts together with 6.8 lbs of force, and a 2nd part to validate the 1st part. Other company sites do Al and Ti, but they're out of state. Our on-site lab only does polymers, but they're pretty darn strong and printing at near micron-level tolerances. They even print in full color. As a gift once, the lab guys gave me a 3D-printed ripe pineapple, including the crown of thin leaves, that I swear would blend right in with this group below, other than the fact it's only about 3" tall.

 

[Firebrick43]

At my co the guys with the least amount of hair still call them G-jobs, but the rest of us refer to them as "calibration prints" to "help make sure the equipment is still meeting expected performance and tolerances".

I've designed hundreds of 3D-printed shop aids in the past few years, to help with various aspects of one-off productions. Mostly just 3rd-hand fixturing, bonding/assembly jigs, etc, but also as check/clearance gauges. I just modeled and sent 2 jobs out today, 1 for a custom spring clip designed to compress 2 parts together with 6.8 lbs of force, and a 2nd part to validate the 1st part. Other company sites do Al and Ti, but they're out of state. Our on-site lab only does polymers, but they're pretty darn strong and printing at near micron-level tolerances. They even print in full color. As a gift once, the lab guys gave me a 3D-printed ripe pineapple, including the crown of thin leaves, that I swear would blend right in with this group below, other than the fact it's only about 3" tall.

He didn't happen to suggest you display the pineapple upside down?

 

[drmarkr]

There is a multi-page, very large, extensive thread on 3D printing right here on this site. I encourage you to post your project there and join in the discussion.

 

[smackey05]

It's very cool that technology today allows you to do this. I did the same with a gauge mount and gauge cup for my 1969 Mustang. Black ASA mount and a black ASA pod. Looks great on the car.

I also recreated clips on the back rear interior panels of my 1969 Mustang that are impossible to find.