Tom wrote: Mon Nov 20, 2023 7:00 pm
Not sure where the pressure points are on that part, but another thing I always keep in mind is print orientation and how it affects strength. If you print a domino standing up, it's pretty easy to snap in half between layers. Print the same domino flat on its back, and there's virtually no way to snap it in half.
Yeah, this is a tricky part in that regard. It seems the weak points are where the vertical pin on the part meets the plastic combo switch housing on the bottom and the metal plate on the top.
The spring pressure introduced by the tip of the lever against the headlight latch, and the tip of the part against the turn signal latch both work together to continually push against the vertical pin. Not much. They are small springs. But continuous nonetheless.
I printed the part standing on its end so that vertical pin prints in a strong orientation. It also provided nice surface finishes for all the other features, especially the ones that would have ended up on the bottom against break away supports otherwise.
I also printed it with a lot of perimeter walls and a dense wide-extrusion infill that spans multiple layers. I'm sure a determined person could still break it, but it would require deliberate effort.
If you're willing
@Tom, I'm happy to send you the STL, or my 3MF from PrusaSlicer with the modifier blocks, layer heights, infill/support settings, etc etc.
I'm still editing a decently comprehensive set of videos for removal, disassembly, reassembly, installation of the combo switch for other DIY-ers. There are some "gotchas" when reassembling the switch, like making sure the brass contact arm for the windshield washer pump doesn't get hung up, blocking that function from working.
However, I think the repair part itself is ready for someone else to try.
I know it works in my car. With all the fresh grease in the combo switch assembly, it works super smooth. Hopefully that means it'll work for other people, too.
