Interest in 3D Printed Replacement Parts?
 

Hey all,

Recently I've begun working on some 3D printed replacement interior parts for my SA and I'm curious if this is something anyone else might be interested in having available. With the popularity of kutukutu1's replacement headlight bushings, I thought perhaps folks may be interested in hard to find replacement interior (or other) parts as well.

Currently in the works are a new center console façade, door handle screw cover trim (not sure what to call it; it's chrome and covers the top door handle screw), and new door handle cups. In the short term parts would be left unfinished, although they can be easily sanded and painted, or vapor smoothed. Material would be some form or cousin of ABS - at the moment I'm playing around with HIPS (high impact polystyrene).

So anyway, just testing the waters for now to see if there's any interest. Unfortunately I'm a little tied up these next couple weeks, but I'll update with what progress is made. And of course I need to make it clear that this is (for now) a side project. If there's sufficient interest it will become less of a side project and more of a side gig :). Also if anyone has ideas for other parts that they'd like to see made available I'll gladly consider them.

you need to heat it up to 130-150f after you print it, it gets hot in the car

True that the parts need to withstand the high temperatures (and potentially low temps) found in a car interior. ABS (and similar materials) should hold up to this just fine. PLA on the other hand, the most commonly 3D printed material, would most certainly not hold up to the heat. ABS is printed at around 250C with a GTT of ~100C. If it ends up being unsuitable for some reason I'll look for an alternative, although it should be adequate for most situations.

I'm always happy to see someone reproduce old parts this way. I have bought several. I know someone made 3d printed door pull cups already. I've had a set sitting around for a while waiting for paint.

Now that you mention it, that does ring a bell. Perhaps I'll skip over those for now to avoid stepping on anyone's toes. The center console piece is my top priority as mine is cracked and multiple repairs have failed - the PO cut it up to fit a single din radio which in turn split it. I'll be making a stock version as well as a couple others to fit gauges and whatnot.

Definitely door pull cups.

Also the little screw caps that hide the screws that hold the rear hatch trim in place. Mine all all missing.

Here is a reach. Wiring harness connectors that plug in to the stock radio. The idiot radio installers that installed an after market radio cut the connectors off from the factory wire harness. Having trouble sourcing the proper connectors that mate up to the factory harness.

1979/1980 rear plate lights. Maybe a design where a camera could be integrated.

On the 80 SAs those chrome covers for the door arm rest would be sweet if smooth and chromed but thats asking a lot. I actually shelled out for 2 armrests just to get those a few years ago.

The other one is simple. The screw covers on the lower center console, 2 on each side. They cover the screws holding the console in place and look ugly not being covered. I have one left intact except for one leg is missing. Its a circle with 2 legs opposite each other and they snap into the edges of the hols so the circle covers the opening.

+1 to what KansasCityREPU said. Don't really need an integrated camera, myself, though.

I'm interested.

I would like to get the plastic trim around the shifter and the trim in the rear where the hatch latch is...
I have a NOS center console if one is needed to 3D scan but it's installed in the car so I wouldn't want a lot of downtime if it's needed.

Good luck and have fun, I just started doing something similar with some AE86 parts.

the biggest issue I’m having is getting plastic in the colors needed for these old cars, like maroon and blue, I don’t want to just paint stuff. There’s also the fun balance of what you fit on a printer vs how fine of detail you can get.

Be prepared for people to ask for your files too. Haha

Ohhhhh, what about the dash defrost vents and the actual trim itself. SA/FB is two different designs, hard to find too. Also door lock trims, and GS/GSL rear model badges the GSL-SE badges are everywhere

Woah, lots of replies. Thanks everyone for the great ideas.

Looks like the list so far includes:
- door pull cups (if someone isn't already making them)
- screw caps for rear trim (I've never seen these, I don't have any either)
- SA rear plate lights (maybe with "camera support")
- SA chrome door bolt covers
- center console screw covers
- shifter trim
- dash vents and trim
- badges
- center console façade

I should note that larger parts are going to be a stretch for the time being. My printer's build volume isn't all that large, although conveniently ABS can be solvent welded so printing large parts in pieces should be a viable option. Really large parts (like trunk plastics) are definitely out of the equation for now due to their size. Maybe down the road, but for now the focus will be on smaller parts. 3D printing also has it's inherent limits so I'll see how it goes. I started messing with 3D printing about five years ago, but it's only now that I finally have my own machine.

Also, I had a little time this evening so I threw together a quick model for the center console screw covers. Note that I'm prototyping with PLA so the surface finish is a bit glossier than it will be with HIPS.

https://cimg1.ibsrv.net/gimg/www.rx7...f7f29820c1.jpg

For whatever reason the photo makes the printed version look larger, but it's not. Tomorrow I'll test fit it to see where we're sitting.

Also regarding the chrome parts, I've stumbled across some products that seem great although they're quite cost prohibitive. I'll continue looking for alternatives, but I think for now any finishing will be left to the end user, we'll see. Still plenty of time to work that out.

member here has been doing this for a while now. also doing the plastic pieces for the arms of the headlights and the wipers(under cowl area).

https://www.rx7club.com/1st-generati...ement-1089623/

Try Eastern Beaver. Sells a LOT of various JDM-spec harness connections...

Stu A
80GS
AZ

Ah, I should have figured it was kutukutu1. I've had his headlight bushings for a couple years now and they're great. Clicking on that thread, however, made me realize I was thinking of a different part than true door pull cups. I didn't even know those were a thing - maybe they're just on S3 cars? I was thinking of the trim pieces that go behind the interior door handles. To me they kind of look like a "cup", I'm curious what the correct name for those are. Anyway, I've seen a lot of these "door handle cups" disintegrated so I figured they'd be a good one to put on the list. In fact I've got a partial test print of one running right now. I don't think I'll ever make the actual door pull cups like kutukutu1 has; I'd never compete with the urethane mold process he uses for those.

On a related note, earlier today I test fitted and revised the console bolt clip/cover and I'm happy to say that after a couple tweaks it fits like a charm now. Below is a photo.

https://cimg9.ibsrv.net/gimg/www.rx7...f8af4491c5.jpg
Yeah, my interior needs some love. The woes of it being my daily driver.

Pretty sure I need that one too.

I 2nd the screw covers. It's a pretty minor trim piece but they just press in and I would guess several people have some that are missing. Color shouldn't matter, easy enough to paint. Here's a pic. You need a sample?


https://cimg0.ibsrv.net/gimg/www.rx7...bcca1fdaeb.jpg

Put me down for 4 of those once you get them ready. Sweet!

Anyone that owns an early car will definitely be down. Some of the little trim parts are near non existent anymore.

Oh interesting, the only screw covers that I recalled looking like that are in the arm rests, but those go to the rear hatch trim? Intriguing. And yeah, a sample would be great. Feel free to pm me with what you were thinking and we'll go from there.

Will do! I hope to have some parts available starting in about three weeks (provided nothing goes awry). Whenever they do go up for sale, those console bolt covers will be some of the first.

That reminds me about the chrome trim that goes on the dash of the 1980 cars and perhaps others. It's just a little line of chrome that continues the ones on the door cards across the dash and glove box. I'd like to get copies of those made as well - most of mine fell off a while ago and disappeared. If anyone has some extra's they'd be willing to lend while I model them I'd greatly appreciate it.

Yes, both inside rear wheel covers have two attachment points that are plugged with caps / covers.


https://cimg6.ibsrv.net/gimg/www.rx7...f7889f6804.jpg

The dash trim you refer to, its a simple shape. I have a small section of that too.


https://cimg3.ibsrv.net/gimg/www.rx7...e6d112c97b.jpg

I suppose you cold just print up different lengths of it to accommodate the different dash panels, but both end pieces are curved to wrap around the dash ends. Not sure how that would complicate things. The chrome strip would still need to be applied too. Possibly this method I previously wrote about could be used.

https://www.rx7club.com/1st-gen-gene...ation-1103911/

Also try Corsa-Technic. I have an FD but they have the majority of the connectors on their site, and they'll even search for them for you, they've done that for me a couple times.

Oh interesting, I never knew there were caps for those. Are there perhaps caps for the A-pillar trim as well? That's another place where there's exposed screws that I have not seen caps for (S3 used clips there instead of screws if I recall correctly).

Neat. I checked my interior and it turns out I'm missing all of mine aside from the glovebox piece. I also didn't realize there were two different styles - one with the two small chrome strips, and another with a single wider strip. I have an 80 but my glove box has the earlier two strip design. I'd assume it was just swapped out at some point. Also nice thread, I'll have to give the process a shot once I get some samples done.

Printing the trim itself should be no harder than the rest of everything, all I really need is the profile and I'll get the length and curves from the dash itself. Unfortunately, with all these interior parts I am unable to replicate the texture of the factory plastics. Well, actually, I can, it just doesn't look so great. Same thing goes for anything that is ever so slightly rounded. Since a 3D printer uses layers, that slight curvature ends up only taking a couple layers worth and so you end up with visible steps and flat spots. The layer height could be reduced, but that increases print time by a fair amount. Currently I've been printing parts flat with 0.16mm layers and the visible face on the build surface. Not necessarily factory, but pretty close and it's better than having a gaping hole.

Speaking of printing, I've got a couple more things modeled. I'm still short on time and so these are pretty tiny parts but....

https://cimg1.ibsrv.net/gimg/www.rx7...315de23f96.jpg

Now completed are window crank bolt covers as well as SA center console switch blanks. Both fit great, although I'm going to make a couple tweaks to the switch blank. Not sure if anyone will want the switch blank, but the reasoning behind it is that my power antenna switch broke a long time ago and so I just removed it leaving an open hole. With the blank the hole can be blocked off nicely or I may make a version to accept a standard toggle switch.

I like the SA switch cover.. I'd be interested in both toggle and blank. I don't need it but still be nice to have I think.

I need the two front covers closer to the shift knob

Any of this available? I need a set for my S2...I think there are 4 on the console...

What the hell.. add me to the list.

I also need a couple of switch h blanks....

Let me know about them and the console side buttons...please...

Thanks....

For 84-85 FB: One that would be of great interest I think, but more of a challenge to 3D print, would be the windshield defroster vents along the top of the dash. Nearly impossible to find intact (at least the left and right pieces) since they're usually exposed to sun and get brittle and break easily.

Their length would make them a challenge. But I'd buy 2 or 3 sets personally. :)

Here is an alternative to the plastic vents. I got one of these without the LRB logo. https://lrbspeed.com/product/fb-defr...-85-usdm-only/

https://cimg3.ibsrv.net/gimg/www.rx7...c9a7a098b1.jpg

Thanks! Yes, I've seen these and was tempted to get one, but want to keep mine as "original" as possible (or at least as original-looking... :P )

Just wanted to post an update since it's been nearly two weeks since I last was in here. I haven't had time to get other parts made up yet, but the plan is to start printing parts in HIPS (the "to sell" material) on Tuesday/Wednesday. That is if my enclosure setup doesn't throw a fit or fumigate me when I switch over to the new filament. Lots of new things getting tested all at once.

The center console bolt cover clips, window crank bolt cover clips, and SA switch blanks will be the first parts available. After that it'll be the hatch trim bolt covers and probably a few other small parts. Once that is rolling I'll get going on larger components. Also yeah, I like the idea of the defroster vents, although I'm going to wait to do those with a different material. Anything large and exposed to high levels of sunlight (defroster vents, exterior parts, etc.) will be made out of a similar material with greater UV resistance - HIPS should stand up fine for little trim pieces. Unfortunately this alternative material is more than twice the price so I'll be holding off on it for a little while.

Later next week I'll be working on getting a second printer online so that should help (still not sure what demand will be). I'll put a message up with details when parts become available, although between now and then there will probably be a couple more updates. I'm still working out the whole batch process idea so bare with me a little while I get this sorted, I don't want to be sending out flawed parts. Parts will be available, I just want to ensure there aren't any glitches in the setup before I put a certain date on anything.

And thanks again for the support. I hadn't figured there would be so much interest, and I also hadn't thought of nearly as many parts as have been suggested. Another couple that came to mind last week were the sunroof crank mechanism and latch. Those will be further down the road, but I've got it jotted down so I don't lose track of it.

@Benjamin4456 Going to need a kanban board to keep track of everything!

Putting in a suggestion for the rear side window plastic triangle finish pieces. They always crack off and end up getting glued back in place, or their just gone.

Also, +1 for any of the demister vents (defroster): s1 I assume are the same as the s2 and are rather simple. S3 I have a NOS left and right gray set still in the bag, but the idea of shipping them just hurts my brain. They are going to get used on my 84 hopefully soon. I had a post in the development section about printing them for a while, might have just been in the wrong section for views. I can take measurements and model the shape for a trade in parts if it comes to that.

Haha, something, that's for sure. A spreadsheet is filling the roll as of now.

:) More parts ideas! Criminy this list is getting long... And yeah, when the defroster vents were first suggested I didn't realize S3 was so much larger, now I see why it will be a fun one. I'd certainly be up for some sort of trade when the time comes, although it probably won't be a for while yet. I'll keep it in mind, and thank you for the offer.


As an update of sorts, well, things broke as things tend to do. Replacements are on their way and should be sturdier, but I am a little behind "schedule". I've been busy with the cabinetry the last couple days and it's mostly functional. One issue is that my filter system is a little too powerful and even though it's recirculating, it is cooling off the print bed enough to trigger a false thermal runaway error (which halts/fails the print). I have a solution in the works for that as well, but it's just one of a number of little things that are slowing down the process. In the mean time I'll work on getting a couple more parts modeled.

I guess put me down for some of those window crank caps

+1 for the window corner triangles! Not too pretty w/o them, and I'd definitely throw money in for the file.

And have you considered MSLA printing? I've had good success with using high detail+durability resin stuff, and it's not terribly expensive unless you're getting a large bed.

Window corner triangles are definitely on the list now, I'll get to them eventually :). I may end up throwing some files up on sites such as thingiverse and whatnot, but we'll have to see. In that case they would be freely available with non-commercial usage restrictions.

I've considered MSLA, although the extra prep and post processing makes it a little less inviting at first glance. Admittedly I have never worked with an MSLA process so perhaps it's not as bad I think, but for now I'm going to hold off (budget being a major factor as my hobby budget is getting a rather thin right now). I need to focus on getting some of these first parts out the door and then maybe after that I'll begin looking into other processes.

Speaking of getting parts out the door I've been fiddling around with HIPS and honestly, I'm not happy with the results. Parts print fine and feel great, but the material lacks the layer adhesion and flexibility for anything that needs to bend (ie, clips). It looks promising for structural parts, however not much else. As such, I have an alternative on the way that I'll be working with. It should offer exactly what I'm looking for with the only downside being a lower temperature tolerance. Essentially it's more UV resistant, flexible, easier to print, and has far better layer adhesion than ABS and the like, although will begin to deform in temps greater than 160F or so. Realistically that should be fine for interior parts (and I will do my own testing regarding it) with only fringe cases exceeding those temperatures. Worst case scenario you take a heat gun and bend it back, which in my mind is better than the tabs breaking off. Also note that this material will only be used for small parts like clips and whatnot, structural parts will use more durable materials with less flexibility and better heat/UV resistance. Everything is a trade-off unfortunately. Or costs a fortune, but that's a trade off as well.

The most recent part I've modeled are the press-in caps for the hatch trim screws. They still need some tweaks, but the bulk of the work is done. For already completed parts I'm just waiting on material and time.

https://cimg2.ibsrv.net/gimg/www.rx7...1c73e4fd5b.jpg

https://cimg5.ibsrv.net/gimg/www.rx7...6665366916.jpg

Damn...those came out nice....I definitely need a set of those for the back hatch trim and the side panels....

I also need a complete set for the back hatch area.

It's been nearly another week so I figure it's time for an update.

First off, other responsibilities have been consuming my time as of lately and so not a whole lot of progress has been made. However, I have made the final revisions to the center console bolt hole clips/covers as well as the SA switch blanks. As I'm a bit tight on time for the moment, I thought I would at least get the files uploaded and available for those who may be able to print them. I still intend to offer these on eBay, however I am unsure when that will be.

Most files will be uploaded under my Thingiverse account, which conveniently is also Benjamin4456. I'm hoping this is allowed per forum rules, but here is a direct link to that page (this is just the files, not an online store): https://www.thingiverse.com/benjamin4456/designs

That link is where anything I upload will be available. Do note that I make some things that aren't for the RX-7 so if you see a few random items scattered throughout that's why. Also for some reason the center console bolt cover/clip is not showing up on my page. Hopefully it fixes itself soon, otherwise I may recreate the post.

Currently I am continuing to tweak the rear hatch trim screw covers, as well as doing some material testing.

I do not know if this has already been said but what about GSL-SE choke hole covers? I know that many fell off leaving a hole that might bother some.

Oh yeah! a choke cover would be nice! I have a 79 though not sure if there would be a major difference.

Guys, you should really send the guy some $$ . He uploaded the files FOR FREE. I don't mind guys selling parts ( those bushings are a lifesaver, but id love to print my own since I own a 3d printer ) but we should all upload design files for free so other people can print them. We could literally rebuild large portions of our interior if we all co-operated and made free files for one another. Like seriously some places will print stuff out for you as long as you have the file.

I suppose I'm not sure which part you're both referring to. All that comes to mind for me is the choke knob, although maybe I'm thinking of the wrong area. If someone has a photo or even just a general description I'm curious where this part is because I honestly can't picture it.

Also, since I'm replying anyway, here's another quick update. I've been quite busy lately with other things but I do have some parts installed in my car that are being "tested". So far so good and really the next step is just getting shipping setup and the eBay side of things worked out. I'm hoping to get the second half of the enclosure done sometime next week which will help with production since it'll cut down the noise. I also have some nylon filament on the way for another project, but I figure I can make some parts for our cars from it as well. Nylon really shines for things like gears and mechanical doohickeys, so if anyone has ideas throw 'em on up here. What comes to mind for now are a few things in the steering column and then perhaps the corkscrew gears in the sunroof mechanism. Of course that's a ways out, as is evident by the speed at which this ordeal is progressing.

Haha, you must have posted while I was typing my prior post. Thanks for the compliment, although really don't worry about funds, there's barely anything uploaded as of now anyway. I am curious to hear what you think of the few parts that are uploaded though. If you ever get around to printing them I'd love to see some feedback on fitment and whatnot. Of course I also tailored the files to my specific printer (which likely is not 100% dimensionally accurate) but still, I'm curious.

Related only in that this is going to be a 3d printed item. I have to go measure a bunch of s2 and s3 center consoles before finalizing the dimensions, fitment, spacing and orientation but you get the idea. Once it's done, I can do a super high quality stl file. It will most likely be a merged solid shrink wrap from the assembly file I'm using. Exporting steps from assemblies to solid parts usually aren't happy. Occasionally iges fixes that. Anyways, working on this for a friend that would like to hold his 32 oz Dunkin donut iced teas :lol:... Shown could be the s2. The s3 one will only have space for one rotor. The shape of the rotor is a scaled down 13b that I modeled. The wall thickness and cutouts of the compression pockets overlap right now and I'm not happy a few things. If you don't have electric windows or the rear wiper, this might be up your alley.
https://cimg9.ibsrv.net/gimg/www.rx7...1d1d81947.jpeg

Simplified non rotor design.
https://cimg6.ibsrv.net/gimg/www.rx7...61b2cdbeb.jpeg

Haha, those are great :). I had planned on making some cup holders as well but nothing quite so fancy, I like the rotor ones. I'll be curious to see how they look when installed.

interested, following