Cannot find a thread, Industrial plastic balls for door hinge repair?

[Richard48Y]

Well, I ran into another obstacle.
Once I removed the old rusted solid door bushings I am left with a nearly square hole at the top and bottom of each door that is larger than the part I want to put in place.
I made a pilot that is the same size as the pivot ball OD.
I will us it while I fill the excess space with epoxy or fiberglass.
If necessary I could make an aluminum insert to do the same thing but without my CNC up and running it would be tedious.
I am unsure why Hachille's doors seem to differ from these S2 doors?

[Richard48Y]

Ah ha!
Hachille has an early S1.
Most of us have S2/TC's
The shape of the door bobbin is different.
Round vs squared.
The elegant solution is a bit more complex for the S2/TC.
A squared insert with flange and countersunk center becomes the nice way to handle this.
I could do them on the manual mill but for production it is one more item for the CNC.
This first car will probably get the bobbins filled with fiberglass or epoxy as I am in a bit of a rush.

[Richard48Y]

Since I have an Ender 3 printer gathering dust I thought maybe I could use it to print the door bushings I need, cheap.
Sketching the model went well, it looks perfect.
But when I import it to Cura it reduces the scale to ridiculously small.
I corrected that by rescaling.
But, when I slice it caps are created over the open areas making the piece useless. 

Anyone here have a clue for me?
So far web search has been fruitless.

[TurboFource]

My son said check the dimensional units as he thinks Cura defaults to mm. He used Prusa slicer on his Ender 3 as he always had trouble with Cura. He said he could slice files if you need him to.

[Richard48Y]

I found that I already have PruSlicer on another computer.
Did the export-import dance and tried again with Pru.
The Pru rendering looks correct,  I will know for sure in a couple of hours.
One thing 3D is not, fast.

I did use MM for the first try too.
If this works I need four to start with.
A dozen for all three bodies/doors.
At least this time I remembered to save the CAD in steps so I may edit it more easily.

A few minutes in and it looks good so far.
This is the cheapest possible material, too bad is is so slow.

[Richard48Y]

I have a nearly successful S2/TC adapter bush for the Hachille type door hinge conversion.
The ID came out about .020" small.
3D does not print a perfect circle, it is a just slightly faceted.
Close enough that a little sanding will save the first part.
I will tweak the geometry for the next one.

As long as the printer is warmed up, I am also printing hinge gaskets. 
Well, I WAS printing gaskets.
One PITA about 3D is getting the part to remain adhered to the build plate.
Long thin parts, so of course they curled just enough to be ruined.
Another try.

[Richard48Y]

Printer adjusted, hinge gaskets now working. 

I've made adjustments and will retry the door bushings in the morning.
OK, the morning when I get up.

[TurboFource]

 

[TurboFource]

Any progress Richard?

[Fotog]

Why do we have to download a file to see your photos?  Any idea?   

[Hachille]

The doors don’t have a well defined opening stop. Hachille added these to give the door some way of stopping in the open position. Otherwise the door might bang into the body and chip paint.

To complete, I also added fiber and resin where the red arrows are in the photo.

[Richard48Y]

Why do we have to download a file to see your photos?  Any idea?   

No, I tried to fix that but had no luck.
I am attaching them the same way I always have.
Something to do with having to change the file extension from the phone default?

[GavinT]

Why do we have to download a file to see your photos?  Any idea?   

The pic is in HEIC format, which is a container for the .jpg file.
The forum software likely can't show it as per usual due to that.

Richard is using an iPhone which arrives with the HEIC format set as the default, these days.
But it can be changed back as many do.
Settings > Camera > Formats > Most Compatible.

[Fotog]

Hmmm.  OK!  Thanks.  Good ol' Apple!  :-)

[Richard48Y]

I suspected something like that.
Been having issues getting the camera to upload so started using the phone.
Looks like a new cable for the camera is due.