Renault 19 headlight switch repair (Spare part)

thingiverse

I Made this to repair my old R19 headlight switch to get it through our Swedish yearly auto inspection. This seem to be a very common problem with the headlight switch on the EU R19 model. The high-beam (full beam) can't be toggled on/off with the Switch arm/crutch . You have to order a complete assy from Renault that will set you back around 250$ as new, if you get a used one you will most likely end up replacing it soon again (I have replaced it 2 times before with a used spare, all have got the exact same problem/breaking point). I printed my final version in ABS, I had to replace the spring that pushed on the lever (that has broken away in the original image) for a stronger one, and adjust and cut it to the right length/strength to get the correct lock/release mechanics working, because I made it a bit thicker than the original so it should not break that easy. I guess the best would be to print it in Nylon but since I was in a hurry I printed a first version in PLA, but finally in ABS to get it a bit more durable. The model is far from perfect and could use some more work. I upload it not as a final perfect repair solution, but a work in progress or a point to start for ppl that think of making their own from scratch or don't mind some after print adjustments and filing (drawn in supports, that are far from optimal and a bit of a pain to remove). By the way, the switch is not intended to be opened, its nailed shut and you have to drill these away on one side. I then closed mine again using some screws and plastic straps. I'm sure you will find getting all parts in place and closing it again "fun" work... (Edit 2018, broke again so this time I'm trying a print with Alloy 910, a bit soft but seems to be working, hoping this will handle the wear better, or at least until i scrap the car)