Rocker Switch Cover Replacements - 3D Print your own

[freff]

Hello,

 

I noticed that some other folks are having the same frustration that I had with obtaining the plastic covers that go over the Mooney rocker switches (breakers).  In my Mooney these switches turn on and off things like the landing light, pitot heat, strobes, nav light, boost pump, etc.    It seems that the vendors don't want to offer the covers alone, and buying replacement switches can run over a hundred dollars each.  

 

So, to get my switches looking like new I created a 3D model of the switch covers.    My airplane is a 1987 M20J.   If you have a similar airplane and want to try these, I am making access to the model publicly available.   It took a few iterations to get the model just right, but I printed these for about $3 each and they fit snugly and have been working well for about the past year with no issues since installation.

 

I recommend sanding, priming, application of text, and application of a clear coat to make your new switch covers look like new.   Some additional details are located at the link provided.   

 

This model is being provided without any guarantees, warranty, nor support.  So good luck, but if do try it, please send me a note so that I can build a list of the years and models that others have or have not had success with.

 

Here is a link where you can see the model and if you choose to order some prints.   I used the white "Strong and Flexible Plastic" option which seems to hold up very well.

 

http://www.shapeways.com/product/YR7FSMMJW/mooney-rocker-switch-cover

 

 

 

Regards
Karl Gerling

[Seth]

Karl-

 

That is amazing.  I may very well order some as I have two switches in that type of shape (broken clip).  Fuel Boost Pump and Nav Lights.

 

-Seth

[Marauder]

Hello,

 

I noticed that some other folks are having the same frustration that I had with obtaining the plastic covers that go over the Mooney rocker switches (breakers).  In my Mooney these switches turn on and off things like the landing light, pitot heat, strobes, nav light, boost pump, etc.    It seems that the vendors don't want to offer the covers alone, and buying replacement switches can run over a hundred dollars each.  

 

So, to get my switches looking like new I created a 3D model of the switch covers.    My airplane is a 1987 M20J.   If you have a similar airplane and want to try these, I am making access to the model publicly available.   It took a few iterations to get the model just right, but I printed these for about $3 each and they fit snugly and have been working well for about the past year with no issues since installation.

 

I recommend sanding, priming, application of text, and application of a clear coat to make your new switch covers look like new.   Some additional details are located at the link provided.   

 

This model is being provided without and guarantees, warranty, nor support.  So good luck, but if do try it, please send me a note so that I can build a list of the years and models that others have or have not had success with.

 

Here is a link where you can see the model and if you choose to order some prints.   I used the white "Strong and Flexible Plastic" option which seems to hold up very well.

 

http://shpws.me/qVub

 

Mooney replacement rocker switch cover copy.jpg

 

 

Regards

Karl Gerling

 

DUDE! You just made a lousy week at work redeemable! I absolutely would be interested in a full set to replace my tired, worn, barely readable covers! We have been working on a group buy for the switches and this was one of the challenges. 

 

I'm sure you know this, but there are two styles of switches. The Klixon version and the ETA ones. Are you able to make both?

[rbridges]

are those ETA rocker switches?  If so, I'm very interested.

[KSMooniac]

Karl,  Excellent work!  Welcome to Mooneyspace too.

 

I can't see how to order any of these from the link provided.  Can you elaborate please?

[rbridges]

Karl,  Excellent work!  Welcome to Mooneyspace too.

 

I can't see how to order any of these from the link provided.  Can you elaborate please?

 

I couldn't either, but I didn't want to look like an idiot and admit it.  

[Marauder]

I couldn't either, but I didn't want to look like an idiot and admit it.  

 

LOL! Too funny. I don't think he is in the business of making them -- at least not yet. Based on what he said, it looks like they would come to you unlabeled.

[freff]

LOL! Too funny. I don't think he is in the business of making them -- at least not yet. Based on what he said, it looks like they would come to you unlabeled.

 

Correct. You will need to finish the parts yourself.  I found a freely available font that is a near exact match for the original lettering and I used some transparency from and office supply store to laserprint the text and then just glued that on with some clear Loctite crazy glue.   Some clear coat spray paint over the top really makes these things come out nice and adds UV protection to boot!

 

I thought about selling these, but since I don't know how widely they will work I am going to just allow others to order them direct from shapeways.  I am not marking them up, so the price that you see is shapeways cost.   This is also why I am not going to guarantee anything but I do hope that they help the Mooney community.

 

I think that I fixed the site so the price should show up for you now if you go back to the link.

[Marauder]

Can you find out if they can make both types? The one on the right is the Klixon version, the one on the left is the ETA version:

[Marauder]

are those ETA rocker switches? If so, I'm very interested.

What covers are you looking for?

[Marauder]

Can you find out if they can make both types? The one on the right is the Klixon version, the one on the left is the ETA version:

The other side:

[testwest]

I verified the site is fixed. Karl's switch looks like an ETA style. There is another designer on Shapeways with a Sensata/Klixon cover style but I have not heard how they are working out by anyone here.

 

We are biting the bullet for some new Sensata E-T-A rockers on our M20J (black) and will have some of the used as-removed white Klixon ones for sale here.

[freff]

DUDE! You just made a lousy week at work redeemable! I absolutely would be interested in a full set to replace my tired, worn, barely readable covers! We have been working on a group buy for the switches and this was one of the challenges. 

 

I'm sure you know this, but there are two styles of switches. The Klixon version and the ETA ones. Are you able to make both?

 

Based on the photos posted, I would agree that this model is for the ETA version.   Sorry I can't help you with the Klixon ones.

[rbridges]

What covers are you looking for?

 

my nav light switch is broken.  The thin plastic part that "clicks" to the rocker is snapped.

[Marauder]

Based on the photos posted, I would agree that this model is for the ETA version. Sorry I can't help you with the Klixon ones.

okay, you just made my Friday suck again...

[Marauder]

my nav light switch is broken. The thin plastic part that "clicks" to the rocker is snapped.

Santa calling.

PM me...

[rbridges]

PM sent.

[Marauder]

Reply sent Ho, Ho, Ho...

[John Pleisse]

I am unclear...will this work for the legions of pre 1980 Klixon folks....our look the worst and have not resolution. Karl, can you help with a model??

[John Pleisse]

Your ingenuity shows how derelict Klixon has been. They can solve our problem quite easily and inexpensively.

[dcastor]

I wouldn't get too excited on these... someone else designed some switch covers very similar to these for the Klixon switches on Shapeways.  Pretty sure I ordered them using the "strong and flexible" material.  The 3d printing method used by shapeways is powder...which means they use some sort of glue to hold together a plastic powder.  I found the powder rubs off very readily with consistent use (as these switches would be) and the powder seems to absorb any grunge that might be on your fingers, and then stains readily.

 

On top of all that, the plastic was not as flexible as the original covers and so didn't grip the actuator as well.  The switch slid around an unacceptable amount (in my book).  The design of the ETA actuators may facilitiate the covers to grip the actuator better, I don't know.

 

Dave C

[DaV8or]

I wouldn't get too excited on these... someone else designed some switch covers very similar to these for the Klixon switches on Shapeways.  Pretty sure I ordered them using the "strong and flexible" material.  The 3d printing method used by shapeways is powder...which means they use some sort of glue to hold together a plastic powder.  I found the powder rubs off very readily with consistent use (as these switches would be) and the powder seems to absorb any grunge that might be on your fingers, and then stains readily.

 

That's why the OP stated that you have to coat the part with a clear paint when you get it.

[DaV8or]

Karl-

 

I'm more curious about the process. How long did it take you to render the 3D file for these covers? What software did you use? Do you think 3D scanning would have worked here?

 

Nice job by the way! I do believe that in the very near future, 3D printing and scanning technologies are going to be instrumental in keeping the aging legacy certified fleet flying with owner produced parts.

[rbridges]

Karl-

 

I'm more curious about the process. How long did it take you to render the 3D file for these covers? What software did you use? Do you think 3D scanning would have worked here?

 

Nice job by the way! I do believe that in the very near future, 3D printing and scanning technologies are going to be instrumental in keeping the aging legacy certified fleet flying with owner produced parts.

 

I read an article in AOPA or EAA that showed an example of someone using 3D printing to manufacture a throttle quadrant cover (or something similar)

[kris_adams]

Amazing ingenuity!