Lexus key - replacement housing

thingiverse

A friend of mine has a 2005 Lexus ES 300 and the casings for two of his keys have cracked. This design is a rugged replacement for the original covers and can be easily opened up when the battery needs replacing. Designed in Moi (Moment of Inspiration) and make in PLA on an Ultimaker 1. Print Settings Printer Brand: Ultimaker Printer: Ultimaker Original Rafts: No Supports: No Resolution: 0.2mm Infill: 100% Notes: Check the orientation before printing. For both pieces the recess should be open and facing upwards so no support is needed for printing. I'm surprised that "Print Settings" doesn't include the material used. I used PLA as I think it more appropriate than ABS (the only other material that I process.) Post-Printing This is what I did: Cleaned excess material from the button cut-outs with a hobby knife. Cleaned excess material from the 5 small holes with a tapered hand reamer. Cleaned excess material from the round and hexagon counter bores and with a 4mm and 6mm hand reamer. As best I could cleaned excess material from the L and U and B cut-outs. Put the two parts together in the correct orientation and dragged the 3mm hex nuts into the neatly fitting hex holes using a 15mm long 3mm button head cap screw. Made sure that the key 'innards' fitted into the recess and that the buttons operated correctly (turned the LED on and off). Assembled the 2 halves together using 10mm long 3mm button head cap screws (3-off). Fully tightened the screws and then turned the body so the the rectangular opening for the key stem was uppermost, rested the body on a plastic cutting board, and tapped the stem home using a soft hammer. Fastened the 2mm cap head through the stem (this screw was salvaged from the original key). How I Designed This I disassembled the old key and scanned the top and bottom housings in a flat bed scanner and saved the files as jpgs. I imported the jpgs into Moment of Inspiration (Moi) and used the images to draw the outline of the recess for the key 'innards' and to draw the size and position of the button and LED cut outs. Then just designed the rest of the covers.