3D-Printed HUD Dimmer Knob...
Le Mans Master
Joined: Mar 2011
Posts: 6,835
Likes: 302
From: Columbia SC
Dan, tried to email pictures via the Forum but could not attach without using a web service which compresses them. PM me with your email address and I will send. If you want to make a functional non original looking **** the pictures I made/can make will do. Frankly with all the compound curves on top and bottom I don't see how you can really do a OEM looking one by pictures. My pictures are against a 2mm X 2mm graph grid to assist. If I had a laser scanner it would be a piece of cake.
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Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
By the way, nearby is a local shop called "MakerPlace". It contains almost everything a hobbyist could want, including electronics stuff like Oscilloscopes, variable power supplies, soldering equipment and even function generators. There are CNC mills, lathes, sheet metal presses/sheet metal equipment, abrasive machines, woodworking equipment, 3D printers, laser cutters, spray booths, fabric and sewing equipment, etc, etc. You pay daily, weekly, monthly, or yearly, I believe, although I don't have pricing. Our local SME chapter will be planning a tour of this place, soon. I'll be sure to attend.
I looked at their web site and they are fairly close to me down in San Diego, CA. They do have an impressive array of equipment and software available which would allow a wide variety of things to be designed and manufactured on-site.
Thread Starter
Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
Dan, tried to email pictures via the Forum but could not attach without using a web service which compresses them. PM me with your email address and I will send. If you want to make a functional non original looking **** the pictures I made/can make will do. Frankly with all the compound curves on top and bottom I don't see how you can really do a OEM looking one by pictures. My pictures are against a 2mm X 2mm graph grid to assist. If I had a laser scanner it would be a piece of cake.
Since Lee DeRaud is pretty close to me, mailing the **** back and forth between us will only take a day each way. So, I think I'll take him up on his offer to use his as a model.
Thanks again,
Dan
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Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
Former Vendor
Joined: Jan 2009
Posts: 12,288
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From: League City Texas
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Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
I've finished the 3D model. Here's a couple of pics of the original and one of the model I built from it.
Interestingly, there is a teeny-tiny spring that goes inside the recess in the back of the **** that keeps it in place.
The lines in the photos are 1/2" apart, so you can see how small these parts really are.
Since I can't make the spring, I've reduced the size of the holes so they are about the same size as the prongs that stick out of the HUD dimmer.
I uploaded the 3D model to Shapeways.com so I can get one printed. Once I get it back from them I can test the fit and make the necessary adjustments.
Interestingly, there is a teeny-tiny spring that goes inside the recess in the back of the **** that keeps it in place.
The lines in the photos are 1/2" apart, so you can see how small these parts really are.
Since I can't make the spring, I've reduced the size of the holes so they are about the same size as the prongs that stick out of the HUD dimmer.
I uploaded the 3D model to Shapeways.com so I can get one printed. Once I get it back from them I can test the fit and make the necessary adjustments.
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Le Mans Master
Joined: May 2006
Posts: 6,774
Likes: 363
From: Midland TX
Impressive, but I am expecting that someday we will be flooded with posts from people who have found their long lost ***** taking up residence in some obscure location... I am pretty sure they are not flying out the window! Right now they are in the same category as the missing sock in the dryer. 
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Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
Yeah, no foolin'. 
Actually I didn't know it was there until I happened to look in the baggie and saw it. Then I wondered what it was and in messing around with the **** saw how it fit into the recess. And, it's not a pressure fit inside the ****. If you didn't know about it, it could easily fall out and be lost to the ages.
After that, I carefully put it back in the baggie and I'm now careful to make sure it was still there every time I took the **** out of the baggie.
I tried the **** without the spring and like Mr. Sam says, you would need some sort of glue to keep the **** in place.
Actually I didn't know it was there until I happened to look in the baggie and saw it. Then I wondered what it was and in messing around with the **** saw how it fit into the recess. And, it's not a pressure fit inside the ****. If you didn't know about it, it could easily fall out and be lost to the ages.
After that, I carefully put it back in the baggie and I'm now careful to make sure it was still there every time I took the **** out of the baggie.
I tried the **** without the spring and like Mr. Sam says, you would need some sort of glue to keep the **** in place.
Thread Starter
Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
I made the recesses in the 3D **** the same size as the two dimmer slider posts.
That should be the only part of the **** that would need adjustment.
Melting Slicks
Joined: Jul 2013
Posts: 2,012
Likes: 23
From: Anaheim CA
Actually I didn't know it was there until I happened to look in the baggie and saw it. Then I wondered what it was and in messing around with the **** saw how it fit into the recess. And, it's not a pressure fit inside the ****. If you didn't know about it, it could easily fall out and be lost to the ages.
I must have had that **** on and off a half-dozen times when I was dialing in the fit of the acrylic blank, and it never fell out.
Le Mans Master
Joined: Mar 2011
Posts: 6,835
Likes: 302
From: Columbia SC
Dan, when I pulled mine off for you I saw it had a spring in it. That was one reason I thought you needed an OEM **** to duplicate. My spring is in there securely. It appears to be a slightly different design than the one you have but similar since the lever has 2 prongs that go into the ****.
Thread Starter
Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
Dan, when I pulled mine off for you I saw it had a spring in it. That was one reason I thought you needed an OEM **** to duplicate. My spring is in there securely. It appears to be a slightly different design than the one you have but similar since the lever has 2 prongs that go into the ****.
The **** Lee sent has a single hole with a blade that comes out from one side of the hole and extends about 3/4 the way across the center of the hole.
The spring goes on the open side of the hole and presses against the prongs to keep the **** in place.
Yeah, you were right about needing an OEM **** to model. The shape is very unusual. It would have been very difficult to duplicate from photos, but was fairly straightforward once I had it in my hands and was able to analyze the shape with my own eyeballs.
Thread Starter
Le Mans Master
Joined: May 2013
Posts: 5,826
Likes: 181
From: Pueblo, CO
If it had fallen out in the envelope I would have never seen it and neither of us would have known it was missing until after I sent the **** back and you went to put it back on the car. Then you would have wondered what I did to your **** to make it not fit any more. (Honest, Lee! I didn't break your ****!
)
Drifting
Joined: Mar 2011
Posts: 1,807
Likes: 331
From: Ocala FL
If you get a working version that you can print are you planning to potentially sell them? I know that I sure would love to get a hold of a new HUD dimmer ****. When I bought my '99 FRC I didn't have one and haven't been able to source one without buying the whole unit. Your prototype sure looks promising. I'd happily be a guinea pig if you need one. 