Hachille door hinge conversion kits S2/TC

[Richard48Y]

I am very close to having door hinge conversion kits fully sorted and ready to sell.
The S2/TC doors require a custom bushing that I am 3D printing.
Material is cheap but the time to print is long.
The hinge balls are inexpensive but the required hardware is not.
The weight savings are very good even with steel hardware.
What I like most about this conversion is that no parts will be wearing the bobbins in either the sills or doors.
I will update this post as soon as I arrive at a retail price.

[TurboFource]

 

[cazman]

Can't wait

[Richard48Y]

I am about to try to print some taper washers.
They can be bought but are expensive.

[Richard48Y]

Final rendition of the adapter bushings is done.
Printer will run 24/7 for a few days.
Making enough pieces for ten cars in this first run.
That is forty bushings, the first eight are mine.
No problem at all to make more as needed.
Not sure what the demand will be, just that I will not get rich off these.
This has been great CAD practice for me, I'm almost good with surfaces and making 3D objects from a single dimension.

Next up will be making the adapter bushings for the bolt to hinge.
Those are coming off my manual lathe as the CNC is not running yet.
They are not difficult and I intend to incorporate a taper shoulder for full articulation of the hinge.
Taper washers and shoulders may be overkill, I need to assemble a door to confirm.
And to take pics/video for assembly instructions.

Pics added. These drop into the door bushings, no drill required.

[Richard48Y]

A small update.
I have found that for S2/TC the simple way to install these is to remove the mud guard at the rear of the wheel well.
No need to cut any access holes inside the car. 

[TurboFource]

For upper and lower Richard?

[Richard48Y]

Yes, both.
I may actually get a door hung tomorrow and take pics along the way.
Bolts will be 5/16" as they are more available here than 8mm.

[TurboFource]

Nice! Looking forward to pics!

[TurboFource]

Any luck hanging a door?

The inserts aren't PLA?

[Richard48Y]

Been tied up fixing the Blunderbird.
Yes PLA, cheap but SLOW to make.
Printing a dozen at a time.
Going into the shop now to see what adjustments I have to make for the aluminum parts.
Then make a set.
Door hang may need a second pair of hands, I will see ASAP.

[Richard48Y]

Made a first attempt at hanging a door.
I had to modify the aluminum bushing, the head was way too thick.
Pics below.

If my VMC was up and running I would make these in aluminum.
More expensive but SO much faster!
For now I have to use the machine available.
I've modified a set of bushings so may get a door fully fit up tomorrow.

A concern has been raised about PLA and heat.
The door hinge area sees very little heat, PLA may begin to get soft at around 150º F?
It prints at 200º F.
If necessary there may be stronger filaments available but I expect PLA to be fine.

I need to add up component cost tonight so that I may post up retail pricing.
My margin will not be huge, so these may be almost more a courtesy than a product.

[Richard48Y]

Added up components.
I will be making the S2/TC bearing adapter by 3D print and the aluminum bushings on my lathe.
The rest will be ordered in bulk.
All stainless hardware.
USPS flat-rate shipping is included.
Have to make a little on them, so $100.00 for both doors seems pretty fair.

A show of hands to get an idea for how many kits to make parts for initially would be good to have.
If I need to keep printing it goes faster when the Ender is already warmed up.

[TurboFource]

Do you have a pic showing access from inside the wheel well?

[Richard48Y]

I hope to get pics and hang a door today.
Car is up on tall stands so I need someone to hold the door for me.