3d printed spare and repair parts

Everything that doesn't belong in the previous categories probably belongs here. Interiour (how are the seats mounted? how to remove the CEM?) and exteriour (how to replace the popup-lights shock absorbers or a door) are discussed here!

Moderators: jifflemon, coyote1980, Rachel

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

3d printed spare and repair parts

Post by Ortovox77 » Sat Oct 06, 2018 8:30 pm

Hi everyone,

My 480 interest has just recently gotten more active again after buying a turbo 94 last year and a ES/GT 95 this year along with my rustbucket Turbo 90 that I have had since 2001.

A month ago after buying the 95 I started restoring it, I started with the interior along with all the electricity. One of the classic things on the 480 is missing clips and cracked plastic part so during my restoration I have started to make small spare parts and repair parts in 3d that I then can print on my 3d printer. This has really helped me getting the car back in order so now I would like to share my 3d models if people here are interested.

So far I have made the following parts.
Door panel bottom clip (2 versions I found on my cars, 90s and 94-95)
Repair kit for the big front seat bakrest knob
Repair kit for door storage compartment with cracked screw mounts
And probably my favorite a repair kit for the electronic window that always break.
AC / Heater knob.

I will start uploading everything on my thingiverse account
https://www.thingiverse.com/Ortovox/designs

Regards Jonas
Last edited by Ortovox77 on Sat Oct 06, 2018 9:48 pm, edited 1 time in total.
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

User avatar
brinkie
Advanced 480 rookie
Posts: 501
Joined: Mon Apr 21, 2014 11:20 am
Location: The Netherlands
Contact:

Re: 3d printed spare and repair parts

Post by brinkie » Sat Oct 06, 2018 8:39 pm

Awesome!!!
Robert.

Present cars: 1994 Volvo 480 GT 2.0i Vase Green, 2010 Volvo V70 2.0F Momentum Mystic Silver
Past: 1981 Talbot-Matra Murena 2.2 Rouge Mephisto, 1995 Volvo 480 GT 2.0i Paris Blue

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Sat Oct 06, 2018 9:47 pm

So now everything I have done so far is uploaded.
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

User avatar
Jaster
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Wed Dec 30, 2009 5:33 pm
Location: Oxford

Re: 3d printed spare and repair parts

Post by Jaster » Sat Oct 06, 2018 10:14 pm

That's excellent, thanks for sharing. I could do with a few clips for the bottom door trim and I have a window regulator in need of repair so I'll give them a go at some point. Do you recommend any materials in particular?
Current: '94 GT & '88 ES
Former: '89 ES

jifflemon
480 Expert
Posts: 658
Joined: Sat Dec 17, 2016 11:03 am

Re: 3d printed spare and repair parts

Post by jifflemon » Sun Oct 07, 2018 9:06 pm

A very generous first post indeed! Can't thank you enough for that.

Now.... how about a post about your cars and their progress? :D

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Sun Oct 07, 2018 10:38 pm

I have printed both parts in ABS and PLA during development but I have used ABS for example in the electric window repair kit since it's supposed to withstand heat and last longer.
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Mon Oct 08, 2018 8:52 am

jifflemon wrote:
Sun Oct 07, 2018 9:06 pm
A very generous first post indeed! Can't thank you enough for that.

Now.... how about a post about your cars and their progress? :D
I can post some pics of my ES 95, the interior is more or less finished except the driver seat that I would like to repair.
The Turbo 94 is in overall good condition, you can see it here https://www.youtube.com/watch?v=UQEEDsnTtXY&t=229s previous owner lent to a review :)
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

User avatar
jamescarruthers
480 Is my middle name
Posts: 1351
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 3d printed spare and repair parts

Post by jamescarruthers » Mon Oct 08, 2018 10:13 am

Well done mate, these are really useful!‎

I'd be interested in four of the lower door clips when you resolve the issue of them staying attached. Are you having trouble with where it meets the metal door or the door card?

Also, would like to repair my original window mechanism with one of your parts.

Would you be willing to print them and post to the UK or is anyone aware of a company that you can send the data to and have them print and post to you?‎
1987 Volvo 480 ES, 507274, 217 - Red
1992 Renault Master Mk. 1. Machzone Chateau camper. 2.0 LPG
2008 Mini convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo
E981 KHM -- ES (509849)

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Mon Oct 08, 2018 12:58 pm

jamescarruthers wrote:
Mon Oct 08, 2018 10:13 am
Well done mate, these are really useful!‎

I'd be interested in four of the lower door clips when you resolve the issue of them staying attached. Are you having trouble with where it meets the metal door or the door card?

Also, would like to repair my original window mechanism with one of your parts.

Would you be willing to print them and post to the UK or is anyone aware of a company that you can send the data to and have them print and post to you?‎
Thanks, it's just nice to be able to share and help other 480 owners.

I updated the door clips yesterday and tested it on my ES 95 and it seem to fit good now on that car which is the one I had problem with before, I will test it on my 90 turbo also and hopefully it will fit good on that one to. The problem I had was getting the clip to stay in the metal part of the door but on my ES 95 it seemed like someone had used force to get a previous clip removed so that's why I will double check on my old Turbo 90.

I found this that might help. Not sure what the prices are.
https://www.3dhubs.com/3dprint/United-K ... 20Galloway

I could maybe print some and send by mail if there are not to many request but since I live in Sweden the cost of printing will be the small cost.

Swedish Postal service will charge the following based on weight in gram
50g ~ 2 euro
100g ~ 3 euro
250g ~ 6 euro
500g ~ 8 Euro

/Jonas
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

User avatar
Jaster
Knows an Aerodeck isn't a 480
Posts: 253
Joined: Wed Dec 30, 2009 5:33 pm
Location: Oxford

Re: 3d printed spare and repair parts

Post by Jaster » Mon Oct 08, 2018 1:47 pm

I've used both 3DHubs and Shapeways (link) in the UK for quick prototypes both professionally and personally in the past. For both sites it's a case of uploading the 3D data you want to print and selecting materials/finish etc then getting a quote. 3DHubs is good if there happens to be a print shop near you, otherwise Shapeways works too. The major advantage in my experience of using a service like that rather than your own printer is that they will charge you once and send you an item, and if the print fails the first three times it's not up to you to babysit the printer.
Current: '94 GT & '88 ES
Former: '89 ES

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Tue Oct 23, 2018 12:23 pm

I just started modelling a replacement part for the position light that easily crack since I had a lamp laying around with good blinker glas.
This is just the first test to see how the size is, so a lot of work left and it's not transparent as it should be.
Image
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

jifflemon
480 Expert
Posts: 658
Joined: Sat Dec 17, 2016 11:03 am

Re: 3d printed spare and repair parts

Post by jifflemon » Tue Oct 23, 2018 5:02 pm

OMG......... :hopping:

On a scale of 1 to impossible, where does the indicator lense sit?

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dragonflyjewels
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Posts: 485
Joined: Sat Dec 18, 2010 10:38 am
Location: Norfolk

Re: 3d printed spare and repair parts

Post by dragonflyjewels » Tue Oct 23, 2018 5:23 pm

jifflemon wrote:
Tue Oct 23, 2018 5:02 pm
On a scale of 1 to impossible, where does the indicator lense sit?
and what about the lens for the rear light cluster ?
Sylvia

Snazzy - 1993 Paris Blue ES red dipstick 2.0i bought 2001
Lethal Lily - 1991 White Turbo with richmod
hubby has
Sven - 1994 Dark Green GT
Evil Eva 1992 Paris Blue Turbo with Robou mod

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Wed Oct 24, 2018 9:09 am

jifflemon wrote:
Tue Oct 23, 2018 5:02 pm
OMG......... :hopping:

On a scale of 1 to impossible, where does the indicator lense sit?
It will be hard, the main problem is the size since most 3D printers are to small and then there is the internal pattern that also will be hard to reproduce.
Will probably have to split it in to two part at least during testing until the shape is reproduced. If I have time I will do some test models.
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Wed Oct 24, 2018 10:02 am

dragonflyjewels wrote:
Tue Oct 23, 2018 5:23 pm
jifflemon wrote:
Tue Oct 23, 2018 5:02 pm
On a scale of 1 to impossible, where does the indicator lense sit?
and what about the lens for the rear light cluster ?
I have thought of doing this but the size and complexity of three different colors in one part is the problem.
An idea I have is making three separate pieces (blinker, break light and reverse light) and then one big shell that they can be inserted into.

But this probably is easier to make with some kind of plastic mold, then you would need a tail light pick apart unfortunately.
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

zapcity
Knows where Volvo is from
Posts: 175
Joined: Wed Nov 09, 2016 4:01 pm
Location: Ipswich, Suffolk

Re: 3d printed spare and repair parts

Post by zapcity » Mon Nov 12, 2018 1:49 pm

jamescarruthers wrote:
Mon Oct 08, 2018 10:13 am
Well done mate, these are really useful!‎

I'd be interested in four of the lower door clips when you resolve the issue of them staying attached. Are you having trouble with where it meets the metal door or the door card?

Also, would like to repair my original window mechanism with one of your parts.

Would you be willing to print them and post to the UK or is anyone aware of a company that you can send the data to and have them print and post to you?‎
Hi James,

Just printed a batch of these as I'm repairing my motors at the moment. If you still need a set let me know and I'll pop them in the post.

Big, big thank-you to Jonas for creating and sharing these parts. Much appreciated.

I can now upgrade my 'new' motors before fitting them.

Image
1993 480GT - coming soon!!
XC60 and XC70 for the daily grind.
C70 Coupé Convertible for the sunny days. Should sell it but can't!

User avatar
jamescarruthers
480 Is my middle name
Posts: 1351
Joined: Mon Jul 07, 2003 3:19 pm
Location: Cambridge

Re: 3d printed spare and repair parts

Post by jamescarruthers » Mon Nov 12, 2018 3:21 pm

Happy to take a set to repair one winder, or two if you can spare them
1987 Volvo 480 ES, 507274, 217 - Red
1992 Renault Master Mk. 1. Machzone Chateau camper. 2.0 LPG
2008 Mini convertible (Mau)

Previous 480's:
J123 CFU -- ES
J449 MNL -- ES
D864 CPV -- ES
L691 JFC -- Turbo
F70 MNR -- ES
H858 FGV -- Turbo
E981 KHM -- ES (509849)

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Tue Nov 13, 2018 1:07 pm

Great to hear that it can help others, if you have any issues or feedback then just send me a message.
I have thought of making one bigger replacement part that holds the wires but I want to see how good this can stand wear and tear first.

I have nearly finished some new 3D models of the two black clips holding the emblem in the grille.
It started when I wanted to renovate the grill on my Turbo 1988 and since it was missing the emblem I took one from an old grille that has seen 310000km so it was really worn. I notices that when taking the emblem apart it is easy that the hooks on the clips break and one clip was already missing.

So I made some new clips that are attached with screws to make them stay and not break as easily, I currently have 2 test versions that I need to decide which is the better.

This is how the grille looks now with the renovated emblem and my new plastic clips
https://drive.google.com/open?id=17PoxA ... b-MVzOb7PO
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

Ortovox77
480 Newbie
Posts: 38
Joined: Fri Sep 14, 2018 10:50 pm

Re: 3d printed spare and repair parts

Post by Ortovox77 » Thu Nov 15, 2018 2:51 pm

I have made some updates to the DRL lamp "glas" and been able to copy it quite close. There are some tweaks still to be made but the main challenge is the print out and material to make it more transparent and minimize the printout patterns.

I will test a better material today and see if it is possible to get an ok replacement DRL glas.
This is how it looks now
https://drive.google.com/open?id=1RVJEk ... 5Nl1TG38J1
compared to the original I used to model from
https://drive.google.com/open?id=1tBVeY ... _9C75Lq8ZI
------------------------------------------------
Volvo 480 Turbo 1994
Volvo 480 ES/GT 1995
Volvo 480 Turbo 1988
Volvo 480 Turbo 1990 (will be scrapped)
BMW Z4 coupe (ESS supercharged)
Saab 9-5 2006
Rotax DD2 Gokart
------------------------------------------------

yorkievolvo
480 Newbie
Posts: 26
Joined: Thu Sep 18, 2014 4:34 pm

Re: 3d printed spare and repair parts

Post by yorkievolvo » Fri Nov 30, 2018 7:55 pm

Greetings Everybody,
bit lost about who's doing what with 3D printed items.
I could use the following 3D printed items:
2x repair kit for window operating mechanisms,
1x L/H & 1x R/H DRL lens covers - I like the look of the ones Optovox77 is developing.
6x door trim clips (the round ones).
Can anyone supply and how do I pay?
Just a thought - would it be feasible for somebody set up a supply point in the UK?
Thanks.

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