Cable Repair Mold

thingiverse

This is a simple mold for repairing severed multi-strand wires using Sugru or a similar casting material. Determine the dimensions of your wire, the diameter of the repaired strands, customize and cast. This was created to repair a broken bike computer wire. See the instructions below for casting instructions. Post-Printing Materials: Sugru, 2 bolts, clamp, soapy water, paint brush, masking tape (optional) Casting instructions: Print with an infill of 25-35% - the mold will be pressed and lower infill may crush Clean any rough edges or surfaces to make a clean mold. The two halves should mate cleanly. You may want to sand both halves to make a cleaner interface. Warm up a packet of sugru while you work on the next steps Place at least two bolts in the mold to help with alignment. A bit of masking tape over the bolt heads will help keep them from falling out while you work. Paint the inside of the mold with soapy water. Cover every surface that sugru will come in contact with. The water will work as a release agent. If you do not use water you may not be able to get a clean casting. With clean or gloved hands open the sugru and form a rough sausage of approximately the same size as the intended casting. Err on the side of using more sugru than necessary. Work the sugru closed on all sides. Push the sausage into the half of the mold with the bolts. Align the other half and firmly push it down. Quickly use a clamp to press the two halves together. Do not allow the sugru to remain in the mold as it will force out the water and get stuck into the mold. Pull the halves apart and gently remove the casting from. Try not to touch it more than necessary. Hang the casting in a safe spot for a minimum of 24 hours. Thicker castings will take longer to cure. Clean off any unwanted flash.