Volvo 940 Handle Repair

thingiverse

I had a broken door handle on my 940 and it was time for an MOT, could I find a replacement the day before...no. CAD and 3D printer to the rescue, the original part is metal with a plastic coating so I've strengthened this one where possible. This part links the door handle to the linkage rod for the door latch mechanism, just remove the pivot pin, place the new part in and replace the pin. the small legs are meant to return the the mechanism but it does that on its own so if they do snap off (which mine did while fitting to the handle) then it doesn't matter. It's in for it's MOT as we speak so no pictures or long term testing but its worked so far. UPDATE: it's held up to regular use for a week now. Print Settings Printer Brand: Ultimaker Printer: Ultimaker 2 Rafts: No Supports: Yes Resolution: 0.1mm shouldn't matter too much though. Infill: 100% Notes: I printed this standing on it's legs with support and a brim, slight sagging in the holes but nothing a small round file couldn't take off. Post-Printing Trim off supports and dress edges with a file. How I Designed This Measurements taken with a digital caliper from the broken original and then the design tweaked to strengthen the main areas. CAD work in Solidworks 2015.