So to fit that you have to take the strut brace off. I've never looked at that, what type/size of tools are needed?
And does it get in the way of the cover that clips over the strut brace?

Next job with the brace was to print in something really strong.

This one was printed with carbon fibre reinforced polyethylene:

http://forum.a8parts.co.uk/attachmen...1&d=1541187671

Unfortunately the print failed as Gizmo (10Kg Maine Coon) chewed through the filament mid-print :ROFL: I didn't mind as I wasn't impressed with the print quality, and it provides a nice view of the stiffening honeycomb inside the print.

The next two were printed in high-temperature PLA. This is a special high quality material which can be annealed in the oven to increase strength and temperature resistance. The blue one is plain PLA, and the black one is carbon fibre filled. In theory, this material could even be used to build cooling system parts - that's going to be an interesting test!

These are shown in the print orientation with the support material for the round recess still in place. This is needed for printing overhangs in some circumstances and must be left in place for the annealing process.

http://forum.a8parts.co.uk/attachmen...1&d=1541187671

http://forum.a8parts.co.uk/attachmen...1&d=1541187671

The carbon filament gives a really nice surface finish

http://forum.a8parts.co.uk/attachmen...1&d=1541187671

The blue is pretty nice too, but not as good as the black. The phone camera really struggled to focus on this one for some reason.

http://forum.a8parts.co.uk/attachmen...1&d=1541187671

There are a few small artifacts in both prints which another hardware upgrade will solve but they're not a problem for prototypes.

They are now cooking in the oven...

http://forum.a8parts.co.uk/attachmen...1&d=1541187671

The bar comes off with four M8 bolts - two on each side. The engine bay seal needs to be lifted up and then the bar slides out and the brace slides on to the bar. Just a 13mm spanner :)

It clears the cover no problem.

I really like the sideways thinking with the cigar lighter to USB.
I want one.

In the D3 I've combined the LPG guage and on/off switch with 2 usb sockets from a kit / adaptor I bought and then mounted all of it on a flat plastic plate located where the cigar lighter socket used to live - it just means it's conveniently neat but you can close the cover when not needed / using +++

This is what the aluminium one looks like in place.

Currently dismantling wiper linkage 😡

Zip

Ah thank you :) I couldn't find any pictures of it. Does it have anything to stop the master cylinder moving upwards? It looks very similar to my mk1 version. Is there anything holding it in place or is it just wedged in there?

Just discovered that contrary to expectation, my mk2 doesn't clear the plastic trim so more fiddling needed there. Also after annealing, the blue one shrunk to be an interference fit on the bar but the carbon one didn't, which is interesting.

You can see it has a lip under the bar that is the same width as the top.

Nothing specifically stopping the mc rising, other than that lip, and the shape of the wedge / angle of the mc.

Bl**dy middle wiper took some persuasion to get off...

Zip

Interesting. Almost exactly the same as my mk1 then.

D2 wipers are such a pain :( I highly recommend GTechniq glass treatment - that way, you don't have to use them as much so they last longer before breaking!

Another great thread, i have thought about 3D printing, but that is as far as i got! hopefully this thread will be as big as the currency mining with all your new parts you can make. I wasn't even aware of the master cylinder flex problem.
Dave