Reproduction mirror switch project

[Rhye]

Hi everybody,

I'm currently running a reproduction mirror switch project and decided to share it with the community since I guess at least some of you may find it interesting. The switch will be totally redesigned inside, using as many standard components as possible. The goal is to make it more reliable and user-friendly while keeping external appearance as close as possible to original. An optional LED backlit decal is also being considered. MJF or SLS technology will be used to manufacture all custom mechanical parts of polyamide.

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If everything goes well with design and prototype testing, a short pre-production series should be available by the end of 2019. The price of final version is estimated to fall between $160 and $200, assuming 20pcs minimum production run.

As for the progress, an early pre-prototype has already been FDM 3D-printed, just to check some initial design ideas and general appearance:

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At the moment, mechanical design of 2 different prototypes is almost ready and MJF 3D-printed parts will be ordered soon:

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I'll keep posting updates as project advances.

[Patrick C]

Wow! Great idea!

[Farrar]

This is a great idea! I just wish 3D-printed stuff didn't look so "layered."

[Parzival]

This is a great idea! I just wish 3D-printed stuff didn't look so "layered."

Is just the prototype 3d printed to check the design? The production part will be molded?

[Rhye]

Is just the prototype 3d printed to check the design? The production part will be molded?

Final parts (and the two soon coming prototypes) will also be 3D-printed, but in totally different technology than the FDM pre-proto part. Surface finish will be like on the sample close-up attached below or even better, depending on post-processing method used:

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[Parzival]

Ok cool, can’t wait to see how those come out!


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[mluder]

Great project!

Cheers
Steve

[dn010]

So this won't be using the steel ball/spring setup as originals did internally? It's a shame, I just rebuilt mine but could do with an upgrade as it is still a bit finicky.

[DavidProehl]

Great project! Will the internals be compatible with original shells? That would be helpful for repairing broken originals.

[mluder]

So this won't be using the steel ball/spring setup as originals did internally? It's a shame, I just rebuilt mine but could do with an upgrade as it is still a bit finicky.

Agreed... It would be awesome if the internals were replaced with micro switches. Of course I have no idea how to do that so...

Cheers
Steve

[Rhye]

Will the internals be compatible with original shells? That would be helpful for repairing broken originals.

No, it will be totally different animal inside - PCB with some standard electronic components will be used.

If there's some need for spare parts for original switch, I could check if it's feasible to 3D-print them, but I need to finish reproduction design first.

If you think of upgrading original shell with new internals - well, that seems possible, but also needs a separate project.

[dn010]

The plastic is by now old and prone to cracking that I wouldn’t even want to reuse the case. Maybe that is just mine though.

[Tomcio]

That plastic was never good to begin with. Add the years and temperature changes and... I'm afraid to touch mine because it might just turn to dust ;)

[bigmac]

Being backlit would be a great idea.


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[Rhye]

After some noticeable delay (: in design finishing (had to focus on another urgent project in the meantime), prototype mechanical parts arrived finally. Here are the results:

Prototype #1 partially assembled, waiting for some machined parts (pivots):

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Prototype #2 assembled fully:

60207 60206

And here's some comparison with OEM switch:

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Decal cut-out will be later filled with white resin, flush with the switch housing. Surface finish is more grainy and totally matt, but this can be addressed by some polishing - I plan to take care of it at the very end of the project. Good news is that mechanical parts of proto #2 work quite well. #1 still needs to be evaluated after completion of assembly.

The PCB design is now in progress. As soon as PCB and electronic components arrive, next step will be a functional test. If any of the prototypes proves to be functional, endurance testing will take place - I plan to prepare a test bench and make at least 10 000 switching cycles in both directions, with ambient temperatures varying between -20 and +80 degrees Celsius.

[Drive Stainless]

Please sell me your old switches!

[Rhye]

Please sell me your old switches!

As for me, nothing for sale at the moment. And I'll always need my OEM switch as a master part.

[Mark D]

I really appreciate the amount of work going into this project. It looks great so far and with the modern PCB it should be more robust than the original. I'd be on board for one of these just to support the efforts.

My OEM switch works but is a little flaky at times so a replacement wouldn't hurt... even though I've only really adjusted the mirror a handful of times in the past 10 years. I've got extended convex mirrors from Tomcio so i can pretty much see everything no matter how the mirrors are adjusted.

[DMC-81]

That's truly amazing! Great job! :bigclap:

[Alan]

Great work. Looks awesome. Very interested. Good luck!
:thumbup:

[bigmac]

After some noticeable delay (: in design finishing (had to focus on another urgent project in the meantime), prototype mechanical parts arrived finally. Here are the results:

Prototype #1 partially assembled, waiting for some machined parts (pivots):

60204

Prototype #2 assembled fully:

60207 60206

And here's some comparison with OEM switch:

60205

Decal cut-out will be later filled with white resin, flush with the switch housing. Surface finish is more grainy and totally matt, but this can be addressed by some polishing - I plan to take care of it at the very end of the project. Good news is that mechanical parts of proto #2 work quite well. #1 still needs to be evaluated after completion of assembly.

The PCB design is now in progress. As soon as PCB and electronic components arrive, next step will be a functional test. If any of the prototypes proves to be functional, endurance testing will take place - I plan to prepare a test bench and make at least 10 000 switching cycles in both directions, with ambient temperatures varying between -20 and +80 degrees Celsius.


Do you need to bench test for that amount of time considering the switches will have data info regarding test info?


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[Rhye]

Thank you all for the positive feedback on the project. I'm progressing very slowly now since I'm mostly focused on reproducing front end of my crashed D body.

@ Mark D
You're first on the list when pre-production switches will be available. :)

So far, PCB prototype has been assembled:

61002

Now I'm waiting for a couple of mechanical parts the test bench will be made of. Simple electronics for automatic actuation of the switch is being assembled/tested in the meantime.

@ bigmac
If you mean the microswitches on the PCB, then yes, their service life data is documented and available. However, all the custom mechanical parts that actuate the microswitches need to be tested for durability - simply because they've never existed before :) so their behaviour over time is still unknown. Final product must be perfect in every way and reliability is the most important thing here.

[Mark D]

@ Mark D
You're first on the list when pre-production switches will be available. :)



Awesome! Sign me up :)

[bigmac]

Please put me on the list. This switch is perfect for my other customers backlit switches.61133


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[bigmac]

Why are there 8 jumpers on the board and does the transistor just control the led?


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[Rhye]

Why are there 8 jumpers on the board and does the transistor just control the led?

No jumpers on the board - these loops are just wires pulled through the holes in PCB to the other side (to prevent bare copper strands bending). The transistor-like component is a constant current source for LED.

[D Knight]

I’d be interested in one too. Anyone have a way to backlight the defog switch?


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[bigmac]

I’d be interested in one too. Anyone have a way to backlight the defog switch?


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Yes you would need to cast a new cap with a white graphic so the light can get through.https://uploads.tapatalk-cdn.com/20190927/8560a2ce964b1f7f1259fec8c29e79d1.jpg


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[D Knight]

Never done that. Do you make them? I’d be in for one plus two spares with heated seat logos on them


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[Rhye]

Coming back to the mirror switch project: I've just finished a test bench and endurance test has already begun. I expect first results late next week. Wish me luck. :)

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https://drive.google.com/open?id=1DsGRpOHZpGEALn6XTBfw0qB-2itxhR2E

[Rhye]

@ D Knight

It should be also fairly easy to MJF 3D-print the switch caps with decal cut-out. I'll probably give it a try and design/order one sample cap along with next batch of mirror switch parts.

[bigmac]

Good idea. I think most people would want a backlit defog switch. Just have to add the 2 spade connectors to the switch and socket and run the wiring and add leds to the switch. Mine come in with the exterior lights.


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[bigmac]

Coming back to the mirror switch project: I've just finished a test bench and endurance test has already begun. I expect first results late next week. Wish me luck. :)

61309

https://drive.google.com/open?id=1DsGRpOHZpGEALn6XTBfw0qB-2itxhR2E

How is the testing going?


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[Rhye]

First of all, I decided to extend my test programme and added 10 000 cycles (20k if you count both directions) in room temperature environment (22 deg C). So far, the switch completed a total of a little over 40 000 cycles (20 000 x 2 directions): 20k in room temperature and 20k in -20 deg C. Not even a single issue was observed during the tests. Both mechanical and electrical parts still work perfectly well. Moreover, I was not able to detect any wear of the moving mechanical parts, so all this looks really very promising.
Here you can see my test bench inside a cold climate chamber:

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To my wife's delight, everything takes place in the kitchen. ;)

80 deg C test is delayed a little - I was forced to make a cooling system for electric actuator 'cause its not intended for continuous operation under such conditions. If the actuator doesn't fail, I'll have the final results in the middle of next week.

[Alan]

I’d also like to be on the list for one of these new mirror switches.

I’m also possibly interested in lit defrost and window switch caps if those come out of this thread as well.

[Rhye]

I'm sorry but the interest in mirror switches is so (unexpectedly) high that my (soon coming, hopefully) preproduction lot (4 pcs) is already reserved. If everything goes well with the project and if first owners will be fully satisfied with the product, I expect that they'll be available again early next year.

[Rhye]

Endurance test officially finished. 2x 10 000 cycles in 80 deg C (176 F) completed - still no impression on any of the switch parts (wear is undetectable). Only my test bench suffered a bit :) - that's why it took a little longer than I thought. Hot climate chamber can be seen here (not much to see because of the foggy double-pane window):

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Now what's going to be done next. I've collected a total of around 20 improvements to the mechanical design and around 10 to PCB design so I'll spend next week or two modifying 3D models. Once it's done, I'll have to focus on backlit decal fabrication and on switch surface quality improvement before I place the order for a 4 pcs pre-production lot. I'll keep you informed.

[Mark D]

Awesome, that looks like a pretty legit test setup you've got there. Keep up the good work! :)

[Josh]

Im very impressed with your testing setup and conditions. Likely much more than the factory unit.

[Rhye]

Yes, I know it's been a while. I've had a lot of other priorities recently and also some issues with my 3D printed parts supplier. I've also started another delorean-related project and it consumes some resources as well.

I've got all the parts on my desk now and assembly is progressing slowly - it turned out to be a bit of PITA since each part has a bit different dimension and some of them have to be corrected manually (MJF accuracy is not so good for serial production of a very small products). It doesn't affect the product's quality but seriously slows the assembly down (some redesign should be done again next time to make the product less tolerance-sensitive). Decal fabrication is another blocking point - after a dozen of tests I'm still not fully satisfied with the result (but I'm pretty close). I decided to make a "smoked" decal so it will be almost invisible in daylight (stock appearance).

If everything goes well with decal and assembly, I think the switches should be ready to ship around mid April at the latest - sorry for a big delay.

[bigmac]

Awesome update. Can’t wait for the new switch.


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[D Knight]

Cool. Thanks for the update. Can’t wait to see the final product. You get a chance to work on the switch caps for defog and heated seats?


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[Rhye]

Cool. Thanks for the update. Can’t wait to see the final product. You get a chance to work on the switch caps for defog and heated seats?

I owe you all my apologies for another delay. My private life affairs have become extremely time consuming recently and I almost didn't have a chance to work on the project since my last update. The only good thing is that the PCB and connectors assembly is almost finished:

63671

Yes, your eyes are not mistaking ;) - there are 9 wires instead of 8. The extra blue wire is for a parking lights backlit decal option - just in case someone wants to route this signal to the driver's door (or already did it). A tiny selector switch is installed on a back side of PCB to choose a light source (ignition switch/parking lights). An extra female pin for door's side connector will be included.

So I'm not going to set another deadline this time - I'll just let you know when the first 4 switches are ready for shipping.

As for the switch cap, here's how the raw 3D print looks compared with OEM part:

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Design needs a bit of refinement (edge blend radii are obviously too small) and it still waits for filling the decal and some brushing. The clip-on joint has to be improved as well (it works but is a bit too loose).

[bigmac]

Looks great. I can’t wait.


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[Patrick C]

Can’t wait!

[Rhye]

Just a little update on what's currently going on. I'm still struggling with that illumination feature and after countless trials I finally developed a method that gives acceptable results, but daylight appearance suffered a bit - decal is slightly darker than the rest of the switch housing. Since the 3D print is not exactly as dark as OEM anyway, I've ordered a special black dye for polyamide (2 weeks delivery time). I expect it'll penetrate the porous surface of the part giving it a permanent deep black tone - I'll try to match it with the decal resin tone so it'll "disappear" as originally intended.

[bigmac]

Can’t wait to see it.


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[Rhye]

Polyamide dye wasn't enough to make the switch body look same as decal area. So I coated the switch with same clear epoxy I'm casting the pictogram to make it deeper black. Here's the result:

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It still doesn't satisfy me - in daylight, you can easily spot where the decal is. The problem is that the surface of the decal is much less grainy than the rest of the switch body. Now I'm probably going to try to "copy" this surface grain by making a tiny silicone mould and placing it on a decal cut-out when pouring the epoxy. This unfortunately means another half month of development, at best.

If only I'd known this would slow the project down so much I'd have made first switches w/o that backlight...

[bigmac]

Looks awesome


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[Patrick C]

Great work!!! This will be worth the wait!

[Rhye]

After a lot of experiments with silicon mould, the result is very close to my definition of perfection. The illuminated area is now only slightly darker than the rest of the switch body while surface grain is almost same.

6491164912

It's an old prototype body I used just for a test so the pattern is a bit different and only vertical arrows are filled. The process itself is so tricky that it's very easy to f...k something up - I'm really afraid I'll end up offering 2 switches instead of 4 so I need more time to improve my technology...

[bigmac]

Fantastic work.

It looks great.


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[Rhye]

I've finally made and tested a special jig with silicone mould insert - here's the result:

6539265391

The process has become fairly reliable and the surface grain of the backlit area is correct now, but it still looks annoyingly darker, at least to me. I'm going to add a small amount of white pigment to the clear epoxy and make more tests with scrapped switch bodies. If it doesn't help, I'll probably leave it like that and proceed with the 4 promised switches (I know, it's been way too long).

[Mark D]

Awesome work, I think the back lighting is looking great.

Just to confirm, you've got me down for one of these right?

[Rhye]

Just to confirm, you've got me down for one of these right?

Yes, the list looks as follows:

1. Mark D
2. Mark A
3. bigmac
4. D Knigh

However, I ruined my only spare switch body so there's no more room for mistakes - I'll do my best.

[bigmac]

Definitely worth the wait.


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[Mark D]

Agreed. I appreciate all the hard work so far that has gone into designing manufacturing these parts. It's not every day that a NLA part is resurrected from the dead like this. It's been really cool to see how things have progressed so far.

[Rhye]

Good news. 3 switches V1.31 are finally completed, tested, packed and ready to go. Since they're still in a prototype stage and the backlit graphics still has some minor imperfections (see development details below), I'm asking just $170/pc + shipping.
Mark D, Mark A and bigmac - please PM me for details and shipping options (if you're still interested - I fully understand it's not a perfect time to spend some money). In the meantime, I'm preparing a short user manual in PDF.

65735

One bad news is that I damaged the body of the 4-th switch beyond repair - made a mistake and my clear epoxy didn't cure fully. I'm awfully sorry for that D Knight - you'll have to wait for the next batch (if you still want one) which is planned for the end of 2021 (after I got enough feedback from users and finish design and assembly of V1.32).

Now some boring details on development. I managed to make the graphics have practically same shade as the rest of the body. It's still slightly visible but only because it's a bit depressed - this is a consequence of the silicon mould pressed hardly against the switch surface to avoid resin leakage. I need to find a method of controlling the pressure precisely. There're also some very tiny air bubbles trapped in the resin (a close look is needed to see them). I'm sure they weren't there when I left the mixture to cure - I always bleed it in vacuum first and check for bubbles with a penscope after pouring. I guess they must have formed when the resin contracted slightly while curing and sucked the air from between the mould and the switch body - this contraction probably also contributed to the former effect of the graphics being depressed slightly.
Anyway, those issues are already on the long list of improvements for the next batch of switches.

[bigmac]

Awesome. I have pm’ed you.


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[Mark D]

Those look fantastic. PM sent.

[D Knight]

Yep still interested. Keep us in the loop. Looking good so far.


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[Mark D]

This showed up today. It's even more impressive in person than in the pics.

http://dmctalk.org/attachment.php?attachmentid=65821&d=1616443782

[bigmac]

Still haven’t seen my one yet


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[Rhye]

Still haven’t seen my one yet

PM sent.

[bigmac]

I’m sure it will arrive soon. I’m amazed Marks arrived so quickly.


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[jawn101]

Rhye - how can I order a mirror switch from you? Can DM or whatever as you like. I broke mine today working inside the doors :tantrum: - bummer, as it's the second one to just fall apart on me. Terrible design, but I can't stand how the Saab one looks.

[Rhye]

Rhye - how can I order a mirror switch from you?

All 3 prototypes are sold/reserved so I can't help you at the moment - you'll have to wait till the end of the year when the next batch is planned. Unless you accept a non-illuminated switch. If you do, I can check if it's possible to rework a body of my 4-th prototype (the one with ruined decal) so it will look like a regular one.

[jawn101]

All 3 prototypes are sold/reserved so I can't help you at the moment - you'll have to wait till the end of the year when the next batch is planned. Unless you accept a non-illuminated switch. If you do, I can check if it's possible to rework a body of my 4-th prototype (the one with ruined decal) so it will look like a regular one.

Non illuminated would be fine by me! Happy to discuss that :)

[jawn101]

Non illuminated would be fine by me! Happy to discuss that :)

You know, come to think of it, non-illuminated is actually my preference, as I'm always worried these illuminated parts won't quite match each other and that would bother me more than no light at all. My DMCH mirror switches are a very different shade of green than my AC panel is and it kinda drives me nuts already.

I'll shoot you a DM!

[bigmac]

I’m so happy with the quality of this mirror switch.

I look forward to installing it.


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[Rhye]

I know, I'm a bit late - a link to the user manual for switch V1.31 attached:

https://drive.google.com/file/d/1s7FRJGpFxUkdyWlQAku8tiMzH_X93Szz/view?usp=sharing

[MrChocky]

I know, I'm a bit late - a link to the user manual for switch V1.31 attached:

https://drive.google.com/file/d/1s7FRJGpFxUkdyWlQAku8tiMzH_X93Szz/view?usp=sharing

Typo:

"undoing it’s bayonet coupling." *its

[Rhye]

Typo:

"undoing it’s bayonet coupling." *its

Corrected - thanks.

[Alan]

Rhye,

These look every good as I'd expected with you "in the driver's seat." I was afraid you were only going to do your initial run of 4. I'm thrilled that you're alluding to another run later this year. Do you have a list for the next run? If so can you let us know who's on it? If not, can you start one... I'd like to be on it. :)

Thanks,
Alan

[Rhye]

Rhye,

These look every good as I'd expected with you "in the driver's seat." I was afraid you were only going to do your initial run of 4. I'm thrilled that you're alluding to another run later this year. Do you have a list for the next run? If so can you let us know who's on it? If not, can you start one... I'd like to be on it. :)



Thanks Alan. I've got you on the list, as well as everyone who expressed interest on this thread or through PMs.

[D Knight]

Has there been any progress made on these? Still interested.


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[Timeless]

Anyone using this?

https://store.delorean.com/105085b-exterior-mirror-adjustment-switch-replacement.html

[Rhye]

Has there been any progress made on these? Still interested.


First of all, I'm still missing feedback from the first users so there might be something worth improving that I'm still not aware of.
Most of the internal parts design changes (mostly to eliminate gluing of the joystick pad) are done and partially tested. A new method of illuminated symbol fabrication is still under development - this is the biggest blocking point at the moment.

[Rhye]

Just letting everybody know that the project is still alive and progressing. The V1.32 batch is almost assembled - except the epoxy clearcoat and illumination. 5 pcs should be ready till mid September.

Main differences compared to V1.31:

- laser-engraved PMMA decal insert (similar to the one on the 3rd photo)
- resettable polymer fuse on PCB
- original RISTS plug instead of a 3D-printed one

68773 68774

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[D Knight]

Cool. Good to hear.


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[kdlex]

Hi Rhye,

Tried writing you, but you have apparently exceeded your storage allowance. Just wanted to say thanks.

[Rhye]

Hi Rhye,

Tried writing you, but you have apparently exceeded your storage allowance. Just wanted to say thanks.

Yeah, I've removed some 10yo messages so I'm now accessible via PM.
Thanks for your interest.

[Rhye]

Update, finally. Here's how the new laser-engraved decal insert looks. Could't force my camera to focus on a graphics - it's actually very clear and sharp. Not invisible anymore (it's white in a daylight), but FAR less problematic in assembly and looks more professional (at least in my opinion). For those who prefer a 100% stock look, I'm going to offer no backlight option in the future.

One more change: the backlight source is now only after ignition switch (draws only around 0.9 mA so it won't hurt).

2 weeks more and the V1.32 batch should be ready for shipping.

69009 69010

[JBaker4981]

That's badass!

[mark w]

How to order one of these switches?

[Rhye]

How to order one of these switches?

The current batch of 5 pcs is reserved (unless someone will quit), but I'll soon be preparing the next one (10 pcs) - end of year, I guess (still a lot of technological improvements). If anybody's interested, please PM me for details.

[Christian Dietrich]

I definitely would like to get one but didn't know if it could be done with blue backlighting since I did all custom blue lighting inside my car.

[Rhye]

I definitely would like to get one but didn't know if it could be done with blue backlighting since I did all custom blue lighting inside my car.

No problem - actually every basic color is possible.

[Christian Dietrich]

No problem - actually every basic color is possible.
Well how do I get on ordering one? I always wanted to do something for the mirrors. My original switch was toast and have a DMC replacement. Yours is just bad ass!

[Rhye]

Well how do I get on ordering one? I always wanted to do something for the mirrors. My original switch was toast and have a DMC replacement. Yours is just bad ass!

I've put you on the V1.33 batch list.

1. kdlex
2. mark w
3. Christian Dietrich

[Midnight Specialist]

can you put me on the list?

[mark w]

I've put you on the V1.33 batch list.

1. kdlex
2. mark w
3. Christian Dietrich

thank you

[Rhye]

can you put me on the list?

You're already on the V1.32 list so your switch should be ready beginning of next week.

[NJP548]

You're already on the V1.32 list so your switch should be ready beginning of next week.

If you plan to make another run, I would be interested. What is the price?

Thanks.

-Nick

[Rhye]

If you plan to make another run, I would be interested. What is the price?

$200 + shipping ($10-$45, depending on option/destination country)

[NJP548]

$200 + shipping ($10-$45, depending on option/destination country)

Ok perfect. I would like to be added to the list. I am in NY (Zip Code: 11795)

Thanks.

-Nick

[Rhye]

The last group photo of the V1.32 family. PMs sent to buyers.

69119

I'll soon start redesign work to create V1.33 (5pcs of 10 still available) - stay tuned.

[1batt4u]

How will V1.33 be?? I am definitely interested. Also will it be possible to get other colors instead of green light?

[Rhye]

How will V1.33 be?? I am definitely interested. Also will it be possible to get other colors instead of green light?

No different externally, just a few (around 20 actually) changes to make assembly process easier.
Almost any color you like (LED availability is the only limit).

[Rhye]

D Knight
Christian 3778
Midnight Specialist


Please check PM's and let me know if you're still interested. I'll wait one week more and offer the V1.32 to the next in queue (sorry, just want to keep this project going).

[Rhye]

1.32 batch sold out. Thank you for supporting the project. The 1.33 version (10 pcs) should appear no later than end of Jan 2023.

[Dhennick99]

Interested in the next batch!

Blue led, if you're able.

69261

Match the interior.

[NJP548]

Just received my switch this morning.

69269 69270

I am VERY impressed with how this came out. I especially like the 'click' sound when you go through the toggle motions.

Well done!

-Nick

[bueller]

Just got mine today and I am super happy with the new mirror switch. Looks incredible and is built very solid. Thank you for filling this need for us!!

[Christian Dietrich]

I owe you all my apologies for another delay. My private life affairs have become extremely time consuming recently and I almost didn't have a chance to work on the project since my last update. The only good thing is that the PCB and connectors assembly is almost finished:

63671

Yes, your eyes are not mistaking ;) - there are 9 wires instead of 8. The extra blue wire is for a parking lights backlit decal option - just in case someone wants to route this signal to the driver's door (or already did it). A tiny selector switch is installed on a back side of PCB to choose a light source (ignition switch/parking lights). An extra female pin for door's side connector will be included.

So I'm not going to set another deadline this time - I'll just let you know when the first 4 switches are ready for shipping.

As for the switch cap, here's how the raw 3D print looks compared with OEM part:

63673 63672

Design needs a bit of refinement (edge blend radii are obviously too small) and it still waits for filling the decal and some brushing. The clip-on joint has to be improved as well (it works but is a bit too loose).

I really love the design of the rear defroster and I would love one for my car as I actually still use it. I also have front fog lights and rear UK fog lights and wonder if a cap could be made with that font also?69310

[rgehrig]

Hi
I also want one.
Let us know when they will be available.
Thanks
Robert

[Rhye]

I also have front fog lights and rear UK fog lights and wonder if a cap could be made with that font also?

I actually gave up with the switch cap for a couple of reasons. First of all, the cost of 3D print itself is prohibitive here - too close to what I could (probably) get for the finished product. Second, the 3D printed void filled with white resin would have rough edges, not to mention the process of making it would be tricky - the only way to improve it would be to develop the same laser engraved decal the mirror switch has. Next thing is the surface grain - the 3D printed cap will never look as smooth as the rest of the switches it sits next to.
Being involved in many other time consuming projects doesn't help here either. If anybody's interested in developing the switch cap further, please PM me for 3D model in STEP format.

[Christian Dietrich]

I actually gave up with the switch cap for a couple of reasons. First of all, the cost of 3D print itself is prohibitive here - too close to what I could (probably) get for the finished product. Second, the 3D printed void filled with white resin would have rough edges, not to mention the process of making it would be tricky - the only way to improve it would be to develop the same laser engraved decal the mirror switch has. Next thing is the surface grain - the 3D printed cap will never look as smooth as the rest of the switches it sits next to.
Being involved in many other time consuming projects doesn't help here either. If anybody's interested in developing the switch cap further, please PM me for 3D model in STEP format.

Well I appreciate your reply and I totally understand! Would look cool though with everything lit up.

[Bitsyncmaster]

I actually gave up with the switch cap for a couple of reasons. First of all, the cost of 3D print itself is prohibitive here - too close to what I could (probably) get for the finished product. Second, the 3D printed void filled with white resin would have rough edges, not to mention the process of making it would be tricky - the only way to improve it would be to develop the same laser engraved decal the mirror switch has. Next thing is the surface grain - the 3D printed cap will never look as smooth as the rest of the switches it sits next to.
Being involved in many other time consuming projects doesn't help here either. If anybody's interested in developing the switch cap further, please PM me for 3D model in STEP format.

Do you use a resin printer? I made my gear shift ball with filled colored epoxy for the printed "decal" and then machined it smooth. I then sanded and polished it and got a glossy surface.

If you have an .STL file, I can print it on my resin printer for a test.

[Rhye]

Do you use a resin printer? I made my gear shift ball with filled colored epoxy for the printed "decal" and then machined it smooth. I then sanded and polished it and got a glossy surface.

If you have an .STL file, I can print it on my resin printer for a test.

I'm using MJF, a chemically/thermally fused PA12 powder (I'm actually ordering prints 'cause the printer itself is worth about 3-4 deloreans). The surface of it can be post processed (polished), but that adds cost and/or time, removes edges and still doesn't help smoothening the outline of the graphics. I know the resolution and surface quality of resin print is superior to MJF but I'm afraid of strength (and maybe UV resistance) being not high enough - unless I'm missing possible advancements in SLA materials/technology. Light blocking of thin walls can be another issue here (painting would probably be required).
Anyway, I've just PM'd you my 3D model files.

[niccolo]

1.32 batch sold out. Thank you for supporting the project. The 1.33 version (10 pcs) should appear no later than end of Jan 2023.

Hi, I would love to buy one, if there are any available.

Also, I'm in Poland, too (Wroclaw)!

[Rhye]

The 1.33 batch got delayed a bit (a bad luck with interference fit - had to order some 3D printed parts once again). I'm slowly moving closer to final assembly and tests - if nothing else surprises me, the switches should be available by the end of March.

69444 69445 69446

[niccolo]

Nice work!

[Christian Dietrich]

The 1.33 batch got delayed a bit (a bad luck with interference fit - had to order some 3D printed parts once again). I'm slowly moving closer to final assembly and tests - if nothing else surprises me, the switches should be available by the end of March.

69444 69445 69446

REALLY excited about this update!!! Keep up the good work!!

[Rhye]

1 non-backlit and 5 backlit switches of the recently finished 1.33 batch are still available - details on PM.

69639

[jimgravina]

Interested...sent you a PM!

[Rhye]

Interested...sent you a PM!

Shipped. Thank you for your purchase!


Just one backlit v1.33 switch available. Next batch planned for autumn 2023. Once again, many thanks to all the buyers for supporting the project!

[paullckby]

Hey there, is the next batch going to be available soon?

[Rhye]

Hey there, is the next batch going to be available soon?

I slowed down a bit mostly because of the pretty low interest at the moment. I guess surface quality may be the main obstacle here and I'm investigating possible solutions for that.
I've also almost finished a slight redesign of the illuminated insert holder and some other minor technological improvements (with no impact on function or appearance). I think the next small batch will be ready late autumn.

70048

[Rhye]

Just a little update on the next batch (V1.34). I've finally tested a new way to get the surface quality closer to that of the original switch. Here's the comparison, from left to right: current design (V1.33), OEM switch and V1.34 (chemically polished).

70241

The new post processing method, apart from being pretty expensive, causes a couple of new issues, like some strange distorsions of the critical geometry of the part, disappearing edges etc. Another redesign is needed to compensate those effects.

[r00b]

Just a little update on the next batch (V1.34). I've finally tested a new way to get the surface quality closer to that of the original switch. Here's the comparison, from left to right: current design (V1.33), OEM switch and V1.34 (chemically polished).

70241

The new post processing method, apart from being pretty expensive, causes a couple of new issues, like some strange distorsions of the critical geometry of the part, disappearing edges etc. Another redesign is needed to compensate those effects.

That looks great, sign me up for one without the illuminated mirror graphic.

[Rhye]

The 1.34 batch is coming (7 stock and 3 illuminated switches) - availability is expected in CW8. I think I can't get any closer to stock look using industrial grade 3D printing technology (the surface is almost uniform now).

70301

[Rhye]

7 OEM-like switches assembled, tested and ready to go. PM me if interested.

70325

A comparison of the latest surface condition with OEM switch:

70324

3 illuminated ones will be available soon.

[kdlex]

Hi,

I?m interested again. My garage guy broke mine. I can?t PM you as it says your inbox is full.

Thanks

[Rhye]

PM sent.
Sorry - that limit is still chasing me. (:

[Rhye]

5 OEM-like switches still available (illuminated ones currently sold out).

70336

[Rhye]

A small batch of illuminated switches available again. OEM-like ones available as well. PM me for details.

71258 71260

[mrsandman]

Pm sent.

Sent from my Pixel 7 using Tapatalk

[dmc6960]

PM Sent!

[JBaker4981]

These are slick!

Do you offer a Blue LED in the unit?

[Rhye]

Do you offer a Blue LED in the unit?

Yes, I can offer it in almost any color. The problem is that since the "tariff war" imposed by US administration, the customs on US side apply regardless of the item's value and are totally unpredictable to me.