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D2 - Body and Exterior Bumpers, bonnets, glass, trims - Everything outside

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  #41  
Old 26th September 2018, 07:32 PM
MikkiJayne MikkiJayne is offline
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Nokia made the non-Bose speakers so it will have fallen off the bottom of that

It'd be simple enough to turn them from aluminium. The challenge then is attaching them to the frame since they're riveted or swaged on aren't they? The bonus of printing them is that you could do it in two halves with locating pegs and bond them together. The challenge of course is finding a printable plastic which is strong enough and can be bonded. Nylon would be strong enough - its probably what the originals are made of - but sticking it is tricky.
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  #42  
Old 26th September 2018, 08:25 PM
HPsauce HPsauce is offline
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Originally Posted by MikkiJayne View Post
Nokia made the non-Bose speakers so it will have fallen off the bottom of that
I didn't know that, but it is a BIG label - 6" by 3".

Looking at the pulleys they have a metal rod through them as the axle and then through a small hole in the backing plate. It has literally been pressed at the end to spread and secure it. So it's difficult to replace.

But yes, a pulley in 2 halves could clip around that. Maybe made in 3 parts it would work - 2 halves to clip onto the "axle" and a grooved ring that fits round them like a tyre? But could it stand the pressure from the cable and stay together? Maybe made from metal and glued with epoxy?

Edit: Pictures attached.
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation".
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.

Last edited by HPsauce; 26th September 2018 at 08:42 PM.
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  #43  
Old 26th September 2018, 09:54 PM
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moltuae moltuae is online now
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Quote:
Originally Posted by HPsauce View Post
But yes, a pulley in 2 halves could clip around that. Maybe made in 3 parts it would work - 2 halves to clip onto the "axle" and a grooved ring that fits round them like a tyre? But could it stand the pressure from the cable and stay together? Maybe made from metal and glued with epoxy?
Or perhaps screwed together, using small grub screws, a bit like this:



Or better still maybe, a central split 'hub' that uses grub screws to secure an outer pulley ring, a bit like this (but smaller):

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  #44  
Old 26th September 2018, 10:07 PM
MikkiJayne MikkiJayne is offline
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Looking at those pics, its probably best to just drill the rivet out and use a button head bolt and a nyloc. Probably a machined Delrin pulley with a bushing of some sort or a small bearing like a 608.
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  #45  
Old 26th September 2018, 10:23 PM
HPsauce HPsauce is offline
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And it isn't, it's moulded into the rather complex rubber seal, so I'll live with what I have for now.
Well, on further investigation it appears that it IS possible to remove the shiny black triangle, and I've done it!
Just 3 little starlock-type washers have to be sprung off and the shiny top surface pulls off with a bit of peeling.

Sadly, there's probably no way of swapping it over on an assembled door as it goes a considerable way down behind the outer skin and the washers are behind the door seal..
You need the window frame off the car and part of the rubber door seal peeled back from the frame as well to get at the fixings.
Part number for NSR is 4D0 853 273. Made in Ireland.

If I'd realised I would have done it mid-job, but there's no way I'm taking it all apart again!
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation".
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.

Last edited by HPsauce; 26th September 2018 at 10:25 PM.
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  #46  
Old 10th October 2018, 04:20 PM
Tjalling Tjalling is offline
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Today I replaced a right side rear window for a customer,
Afterwards i investigated the triangle thingie.
In my opinion if you remove the inner plastc triangle the take out the t30 bolt losen the rubbers it would be possible to fiddle the triangle out without taking it all apart.

I'm gonna make an attempt after the ADI ,and wil keep you informed
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  #47  
Old 10th October 2018, 04:51 PM
HPsauce HPsauce is offline
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Originally Posted by Tjalling View Post
I'm gonna make an attempt after the ADI ,and wil keep you informed
Hope to see you at ADI, I'm aiming to be there too!
__________________
2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation".
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
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