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Daily banter For everything, and anything that doesnt fit in elsewhere |
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#1
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What's in the workshop? A 3D printer!
Ok, so its in the kitchen, but I thought I'd stick to the theme
Frustrated by the declining availability of genuine parts, I decided to start making my own, and to that end I bought a 3D printer - a Creality CR10-S This is a Fused Deposition Modelling (FDM) machine. It takes plastic filament, melts it in a mobile print head, and lays it down a layer at a time to build a solid object. Obviously the first thing I printed was a cat It lasted four days before I voided the warranty I changed the cheap original fans for some quieter ones I then set about printing a few upgrades for the printer. I love that it can make its own parts! This filament was supposedly aubergine. It turns out more like pink, but it makes a pleasing contrast to the black anodised aluminium so I don't mind. I then printed an army of calibration cats while dialling in the settings on the machine |
#2
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Once I'd got the printer working nicely I had a go at making something useful. I made this design in Tinkercad which is a free online 3D cad program.
Laying the design down Done Took apart a USB cig lighter charger Took apart the D2 cig lighter Mounted the USB sockets in the printed parts and then mounted that assembly in the cig lighter surround USB charging points instead of a cig lighter |
#3
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Made some parts to fill in the holes in the air box after removing the secondary air pump.
These two pieces snap together to fill in the hole from the air hose and electrical connector. and these plugs fill in the bolt holes A bit of adhesive for extra security Fitted in place |
#4
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What size of items can these print to, as all I've ever seen produced from 3D printers seems to be small trinket sized items, like your cats? Really thinking about the printing of the D2 foglight grilles, as was mentioned elsewhere.
Will you be having a "What's cooking in the kitchen?" thread, where we have to guess what the mystery printed object is for?
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2001 A8 D2 FL 3.7 Q - LPG Conversion, Engine: AKC, Gearbox:FBB, Colour:LY5X Aqua Blue pearl effect, Interior:WJ light beige/dark beige valcona leather with burr walnut inserts My DIY jobs - Replaced alarm horn, Replaced Coolant Temp sensor, Updated RNS-D firmware, Installed Reversing Camera and Digital TV, Dashcam Installation, Retrofitted Rear Blinds, Auto-Dimming Rear View Mirror, Chrome Boot Struts Sold! 2008 S8 D3 5.2 V10 - Engine: BSM, Gearbox:KLW, Colour:LY7F Suzuka Grey Pearl Effect, Interior:Black/Black with Silver/Black valcona leather with carbon atlas inserts, Bang & Olufsen, Heated windscreen, Soft-close doors, TV, DAB, AMI, Quad Zone, Auto Boot, Auto dim Mirrors, Keyless entry, PDC with rearview camera, AFS II Headlights My DIY jobs - Fan Jet Windscreen Washers, Retrofitted Electric Side Blinds |
#5
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Quote:
This machine has a print bed of 300x300mm so it won't do a foglight grille in one piece, but there are bonding agents for many of the printable materials which are as strong as or stronger than the material itself so its entirely feasible to print them in two pieces and bond them together. It would do a two-piece grille ok though. I think I mentioned in the other thread that the challenge with the grilles is getting a good enough surface finish on them, and that's going to take some experimentation. I have some carbon fibre reinforced material which prints with a nice satin-sheen finish, but I don't know how durable it is, and its expensive. ABS can be vapour-smoothed with acetone, but its difficult to print and would leave a gloss finish so that would need painting to match the factory look. Plus of course we still need to scan them in and manipulate the scan in to something printable. Tbh the grilles project wasn't the primary reason for buying this machine - its more of a future aspiration at this point. Its main use is printing smaller functional parts like clips and brackets which can't be bought from Audi any more, such as the clips for the radiator breather pipe or the starter junction box. Maybe even door card clips, although that's a bit of a stretch but worth a try. Radio adapter plates too. Oh, and the brake master cylinder brace which I will post up shortly |
#6
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Cool
So do you have access to a 3D laser scanner to scan the original parts MJ? A 3D printer is something I've been meaning to buy for a long time. I've been waiting for the technology to evolve more, but I'm also waiting until I have a bit more free time, because I will no doubt become completely engrossed by it just as soon as I get one. Have you seen Carbon's 3D printing technology? I think it's only a matter of time before this level of 3D printing becomes affordable and commonplace: https://www.carbon3d.com/ https://www.youtube.com/watch?v=zXE-icw28n8 https://www.youtube.com/watch?v=O2thSsQrZUM
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Mark ------------------------------------------------------ 2002 FE S8 Ebony Black Pearl ------------------------------------------------------ ------------------------------------------------------ Cars Owned: The Tesla Era: 2020 Model S Performance Ludicrous+ (present) (Black, with all black premium interior and carbon fibre décor, 21" sonic carbon twin turbine wheels and FSD capability) The Audi Era: '97 A8 4.2 (Ming Blue) --> '96 A8 4.2 QS (Dark Green) --> '02 FE S8 (present) The Citroen Era: '84 BX 1.6 RS --> '89 BX 1.9 DTR Turbo --> '94 XM 2.0L Turbo --> '96 XM 2.0L Turbo Exclusive --> '00 Xantia Activa 2.0L Turbo The Banger Era: '76 1.2L Lada VAZ-2101 (Ruski Fiat 124) --> '80 1.7L Morris Ital HL, finished in Ermine White and Rust |
#7
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I don't have a scanner yet, but I'm planning to contrive one from an Xbox kinect
The Carbon stuff is very very cool indeed. I was using resin stereolithography 25 years ago to make prototypes of injection moulded parts. They were brittle and fragile, and took many days to make anything useful. No one had even thought of the term '3D printing' at the time. Now you can make production parts using essentially the same technique. Thanks to open source software to drive them, the technology has evolved to the point where a desktop FDM printer is <£200 (mine was £350) and can make entirely usable things of remarkable quality. I printed this from wood - essentially MDF filament: It is totally engrossing too. I can sit there watching it make things, listening to the stepper motors singing, for far longer than necessary! |
#8
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Very cool stuff MJ
Looking through the list of items you have made so far. I would guess you will be able to make the headlight bracket arms too? https://www.ecstuning.com/b-genuine-...d0998121a~oee/
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Johannes _________ Audi S8 -99, Pearlescent, Alcantara/silk napa leather, Burr walnut insert, Alcantara roof lining upper pack A8 32V engine ----- Jeep Grand Cherokee -98 |
#9
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Ok the brake master cylinder brace that a few of you guys have been waiting for
I had noticed when working on the manual swap that the brake fluid reservoir moved around an alarming amount when I stood on the brake pedal. It seems from the 'brake block' thread that I wasn't the only one, but there's nothing on the market for this any more so I decided to make my own. Vid of the unsupported master cylinder here Started off with a cad model in Fusion 360: Printed it in the aubergine filament Installed: I took a video of this one installed and it didn't actually do much because the whole assembly is mostly rotating around the top bulkhead where the pedal box is mounted rather than pushing forwards. This brace stopped it moving forwards, but didn't prevent the master cylinder lifting up. So, a few modifications to the model resulted in this: Printed one in some cheap red PLA Tolerances weren't good on this so I tweaked the dimensions slightly and printed in some better material This one works pretty well as you can see here |
#10
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Those are on the list
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