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Rocker Switch Cover Replacements - 3D Print your own

freff

By freff
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freff Apprentice

freff

Posted
Posted

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

 

post-12185-0-75435700-1393021175_thumb.j

 

 

Regards
Karl Gerling

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freff
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

Pinecone
Pinecone

A friend did a 3D modeling of the ETA switch cover.  He sent me a couple of samples to try.  Need to get over to the plane and try them. Once the file is finalized, I have been talking to AH1 pil

freff
freff

HI guys   I wanted to answer a couple of your questions.   If you order using the material that I recommended, shapeways uses an SLS process which uses a laser to bind a plastic powder together.  

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Seth Grand Master

Seth

Posted
Posted

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

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Marauder Grand Master

Marauder

Posted
Posted

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

 

attachicon.gifMooney 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 Grand Master

rbridges

Posted
Posted

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.   :D

Marauder Grand Master

Marauder

Posted
Posted

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

 

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 Apprentice

freff

Posted
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Posted

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.

testwest Experienced

testwest

Posted
Posted

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 Apprentice

freff

Posted
  • Author
Posted

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.

  • 2 weeks later...
dcastor Collaborator

dcastor

Posted
Posted

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 Grand Master

DaV8or

Posted
Posted

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 Grand Master

DaV8or

Posted
Posted

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 Grand Master

rbridges

Posted
Posted

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)

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