Need help reproducing a part...

[Alex Franke]

A little plastic latch broke on the floor console of my Lincoln LS. (Gee -- I wonder why they made it out of plastic...) It's a pretty common problem and I know several others that need the same part. Of course, you can't just buy the little plastic latch anywhere -- you have to buy the whole console lid for like $300.

So I figure I can spend $300 on a new lid and throw out an otherwise perfectly good one, or I can spend up to maybe $400 learning how to reproduce the part (the $100 premium because I would value the casting/molding education and experience). And if I can effectively reproduce it, then I can help some friends out, too.

But it doesn't look simple because of the undercuts, and I think it would be difficult to re-model and 3D-print.

Any ideas?

Here are a couple photos... You can see on the lower picture where a pivot shaft extended to either side. These extensions broke off, but I still have them. BTW, superglue was only effective for a few months.

[BT3 WOODOG]

I would try ebay !!!

[bigstick509]

Check out this link. It seems like it might fit your needs and price point.
http://www.sciencedaily.com/releases...0331153010.htm

[pelligrini]

I just looked on ebay, didn't see any little parts like that in my quick searches. There were a few complete used consoles for $100.

But I think Alex wants to buy some new toys.

[Uncle Cracker]

Try the auto recyclers or junkyards in your area. Most of them are wired together now, so they'll find you one if they don't have it.

[cabinetman]

Of course, you can't just buy the little plastic latch anywhere -- you have to buy the whole console lid for like $300.

When you say "anywhere" does that include the parts department at the Lincoln dealership?
.

[Alex Franke]

Check out this link. It seems like it might fit your needs and price point. http://www.sciencedaily.com/releases...0331153010.htm

I'll take a look at it, but I don't think 3D printing will work for this because it requires a 3D model, and I don't think this would be a very easy piece to model. 3D scanning is one option, though. I tried a DIY 3d scanner with only marginal results -- because it's flat black the camera didn't pick up the laser lines very well. Shaking it in flour worked better, but not well enough.

But I think Alex wants to buy some new toys.

Guilty as charged

Try the auto recyclers or junkyards in your area. Most of them are wired together now, so they'll find you one if they don't have it.

Good tip -- thanks! I'll make a couple calls. But of course this would mean I don't get to learn how to make it myself....

When you say "anywhere" does that include the parts department at the Lincoln dealership?

That's correct. The parts department only sells the whole lid assembly for roughly $300.

[Mr__Bill]

You should be able to make a sand casting of it out of aluminum. Just carve one out of styrene and pack casting sand around it and then pour in the molten aluminum. Or get a block of aluminum and go at it with your dremel tool.


bill
on the Sunny Oregon Coast

[LCHIEN]

of course buying used ones will simply have them break in short time... same poor design as the ones that are breaking now. and they are already down the wear curve.

[pelligrini]

Sounds like a perfect opportunity to to a console design is rosewood, that can be set up for production runs. This is a woodworking forum, most of us tend to think in wood solutions to problems.

Or you can take a tip from my wife; adhesive velcro pieces, they can be used anywhere...

[cgallery]

You drive an LS? I figured you for a Subaru.

Anyway, are the plastic pivots the only broken part? Sorry, I can't tell from the photo.

[crokett]

I always figured him to drive a Volkswagen. And no, I don't know why.

Is there room to drill out the part and epoxy in some metal pins that won't shear?

[Uncle Cracker]

of course buying used ones will simply have them break in short time... same poor design as the ones that are breaking now. and they are already down the wear curve.

I have an LS with many used parts in it, and no problems with any of them. For what all new parts would've cost, I could've bought a Porsche...

[Alex Franke]

You should be able to make a sand casting of it out of aluminum. Just carve one out of styrene and pack casting sand around it and then pour in the molten aluminum. Or get a block of aluminum and go at it with your dremel tool.

I've been considering this idea, but I don't think I can re-carve this piece. And I don't know how I would make a mold because of the undercuts, either. I sure would like to figure this out, though. This part really does need to be metal... If I could get it into the computer that would work, too. I wonder if I could snap some pictures and try to "reverse engineer" the design in some CAD software...

of course buying used ones will simply have them break in short time... same poor design as the ones that are breaking now. and they are already down the wear curve.

It's true -- this is actually the second time it's broken. It broke shortly after we got the car but they replaced it under warranty.

You drive an LS? I figured you for a Subaru.

Anyway, are the plastic pivots the only broken part? Sorry, I can't tell from the photo.

Subaru? Interesting... Why's that?

Yeah, that's the only part that's broken -- one ~1/2" shaft protruding from either side that make the fulcrum of the lever.

I always figured him to drive a Volkswagen. And no, I don't know why.

Is there room to drill out the part and epoxy in some metal pins that won't shear?

Volkswagen? This is insightful!

I don't think there's enough room to drill it out. That might be what I try, though, if all else fails.

I have an LS with many used parts in it, and no problems with any of them.

You're lucky! This is the second one for my car, and others have the problem, too. Maybe the lid is fastened just slightly off or something so that it puts too much pressure on the part when it's opened. I dunno, but so far this is pretty much the only thing I dislike about the LS -- loads of fun to drive!

[eezlock]

need help reproducing a part.....

Alex, you might want to try a good brand of two part epoxy. Devcon and
others work really well. I have had good success with epoxies I have used
and do recommend them. Be sure to clean of any excess old super glue
or other adhesive before applying the new epoxy.