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| D2 - Body and Exterior Bumpers, bonnets, glass, trims - Everything outside |
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#1
20th January 2020, 08:45 AM
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This is what I'd do for TPU:
Each half would clip over the cable and then be bonded together with polyurethane sealant. The completed thing could then be pushed in to the panel like the original. You'd need support round the groove to print this though, unless you printed it vertically with support under the rebate. I don't know how TPU behaves with support though. 
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#2
20th January 2020, 09:18 AM
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 May I ask how long you have been doing CAD? In fusion 360 I have designed some jigsaw like connectors for multi piece objects that work quite well. It would probably work for TPU as well. This groove was printed with supports and was no problem to clean up (ninjaflex).
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1998 D2 S8 Jaspis Green
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#3
20th January 2020, 09:38 AM
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I've been doing 2D CAD for about 25 years, but 3D for only a year since I bought my CR-10S. From a 2D background the leap to extruding a 2D object in to 3D space is fairly simple, but Fusion is very different to AutoCAD despite both being made by Autodesk. I did my first 3D object in Tinkercad too but quickly found its limits and moved on to Fusion360.
Check out a chap called Lars Christiansen on Youtube - he has some great tutorials which is how I got started  I'll upload these STLs on to my web server and pm you the links shortly 
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#4
20th January 2020, 10:07 AM
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That looks flipping brilliant! Well done MJ
Now onto the D2 fog light grills!
__________________
 2002 D2 S8 - Avus Silver, Valcona red leather, Dark Myrtle wood inserts, Heated rear seats, Heated windscreen, Auto dim rear view mirror, Bose, Xenon Plus, Servotronic, Extended leather, Heat & UV Reflective glass & Ski hatch. Gearbox went bang but she's sleeping safely away.
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#5
20th January 2020, 02:07 PM
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Here is a picture or two: Brilliant design MJ! I bet it fits like a glove... Printed @ 100% infill with supports everywhere and a brim. Print time was 1hr 24 mins @ 30mm per second print speed. I will have a go at installing tomorrow and report back. Here is the time lapse video of the print for a bit of fun! vid.mp4
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1998 D2 S8 Jaspis Green Last edited by C4R 100N; 20th January 2020 at 02:12 PM. Reason: it's not fusion 369!
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#6
21st January 2020, 03:41 AM
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The one on the right side of my vehicle was missing so bonus! Seems to fit perfectly with no gluing, although probably wise to as the parts may fall into the panel void I suppose. I'll leave mine unglued and see how it fares. Thank you MJ for allowing me to print these and I hope you don't mind me posting the results here. I probably should have asked first I am thinking in hindsight.
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1998 D2 S8 Jaspis Green
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#7
21st January 2020, 07:40 AM
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Even though I know how it works, its still slightly magical that something I designed on my computer can then be a real object on the other side of the planet a short while later
 It looks like it fitted quite well too. I'd definitely glue that design to make it weather-tight, but that might not matter in some parts of Australia I guess? I need to get my machines printing TPU now!
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#8
21st January 2020, 10:02 AM
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MJ, I know that feeling of awe. Over 25 years back I wrote an XL worksheet with embodied macros that I used at work. I passed it onto others and they used it in UK and Europe. A couple of years back I attended a reunion and one of the young guys told me that he had seen it being used on a training course in the States. Magic. Shame I couldn't copywrite it!!!!!
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Ray at Wigan Pier 2014 A8L D4 4.0TFSI Gold (Sticker says "Beige") Can't leave you in a black smoke cloud anymore.. In progress, Nothing left to do.  Gone 2004 A8 D3 3.0 TDI. Ebony Pearl Black (with little bits of other colours and glitter)
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#9
21st January 2020, 11:26 AM
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And she is right to a degree - you could not courier a part as quickly, even in the same city usually. That is assuming that the part is still available to buy and not NLA. It is entirely possible that you could conceive a design that did not exist in the world and yet have someone on the other side of the planet holding the realised conception in their hand in less than an hours time, such is the wonder of modern technology! When I was a boy I remember watching Lost In Space and being well impressed at the magical machine that you simply pressed a button to select your desired object and Voila! the door to the machine was opened and there was your desired item....reality is approaching this idea. One day we may not even have to go shopping, or to the hardware store - we will simply print our own screws, nails, and what-nots. Look! We are doing it already! Quote:
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1998 D2 S8 Jaspis Green
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#10
22nd January 2020, 02:12 AM
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It still rains here Michaela! Quite heavily this past week too (which hopefully put the brakes on the Victorian bushfires a bit). Pity NSW isn't getting similar downfalls... So with the glue, you mentioned polyurethane (which would have better adhesive qualities than silicone), so by that, do you mean Sikaflex?
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Cheers Marty  ____________________ Current: 2001 Audi S8 - Brilliant Black with Black interior, C5 RS6 rims (whenever I actually put them on...), Solar Sunroof, Tinted side and rear glass, RNS-D, Grom, Bose, clunky old phone in arm rest! 2002 Audi S8 - Project Replacement head coming arrived thanks to MJSilver with Black interior. All features as the '01, with the 'S' mode auto shifter. Dodgey rear tint (need to find a way to get rid of that). Family: 2009 Volvo XC90 V8 R Design - has a louder more obnoxious exhaust than the S8, sounds great! Love this thing - Q7 was double the price, and certainly not double the car! Sold: 1997 Audi A4 - Hamilton's Club Sport, Achat Grey (will miss the old girl)
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