Anti-lock brake cable clamp replacement
Aug 28, 2022 21:23:48 GMT
dhamblin, uuu, and 1 more like this
Post by Roger on Aug 28, 2022 21:23:48 GMT
I needed to replace the front discs and pads on the Smart Car, and while doing that I was going to replace the broken cable clamp pictured below. I don't know if this was damaged by a stone or something else, but it's sheared where it clips onto the lug and doesn't stay put. I've had it held on with cable ties for a while, so I ordered new ones while I was at it.
PXL_20220828_211024096 by Timothy Froud, on Flickr
What I didn't realise was that the new ones are different, and they can't be fitted. I just assumed that they were an improved version, but apparently not.
So rather than wait and try to get the right ones, I decided to design better more robust ones and 3d print them myself in PETG. This is what I came up with, just copying the clip end details but using a stronger attachment method. The blocks on the end register with the hole and cutout in the 2.5mm thick bracket that's welded to the strut. There's a slot for a Stainless Steel square nut and I'm using a penny washer, spring washer and hex dome head screw, all Stainless.
Cable clamp 3d print by Timothy Froud, on Flickr
Here's how it looks on the car.
PXL_20220828_183227542 by Timothy Froud, on Flickr
It took about 40 minutes to design and model, and an hour and a half to print. It's way stronger than the original, so I'm happy with that. I'm just printing out one for the other side which I'll do tomorrow.
This is what I love about 3D printing, it's possible to make complex things that simply aren't feasible to make quickly any other way. Once you've modelled it, it's as good as made.
PXL_20220828_211024096 by Timothy Froud, on FlickrWhat I didn't realise was that the new ones are different, and they can't be fitted. I just assumed that they were an improved version, but apparently not.
So rather than wait and try to get the right ones, I decided to design better more robust ones and 3d print them myself in PETG. This is what I came up with, just copying the clip end details but using a stronger attachment method. The blocks on the end register with the hole and cutout in the 2.5mm thick bracket that's welded to the strut. There's a slot for a Stainless Steel square nut and I'm using a penny washer, spring washer and hex dome head screw, all Stainless.
Cable clamp 3d print by Timothy Froud, on FlickrHere's how it looks on the car.
PXL_20220828_183227542 by Timothy Froud, on FlickrIt took about 40 minutes to design and model, and an hour and a half to print. It's way stronger than the original, so I'm happy with that. I'm just printing out one for the other side which I'll do tomorrow.
This is what I love about 3D printing, it's possible to make complex things that simply aren't feasible to make quickly any other way. Once you've modelled it, it's as good as made.
