Klixon Covers Version 6

[Marauder]

I just received my Shapeways Klixon version 6 covers. This is the one that is supposed to be a tighter fit. I was hoping to take measurements of the new covers along with the pictures. Unfortunately my electronic micrometer's battery is dead. I will get the measurements later.

At first glance, they looked like they would be a great fit. 

Upon installing one on a Klixon switch, I thought it was going to be a magic moment.

They fit okay but I noticed that unlike the original Klixon, once installed, the top of the cover will pull away from the switch. It wasn't enough to fall off, but it clearly was not cinched up like the original cover.

You can see in these pictures how the cover pulls away from the switch. You can't do that with the original cover. You need to pry the original off. Interestingly, the Shapeway cover doesn't fall off, but it sure looks like it will.

After eyeballing things for a while, it appears the difference is due to a slightly wider (~2mm) tab on the original. 

I have a busted switch that I will see if I can find a way to glue to top of the cover to keep it on. I will also send the designer a note to see if this can be a little bit wider.

[aviatoreb]

28 minutes ago, Marauder said:

 

I just received my Shapeways Klixon version 6 covers. This is the one that is supposed to be a tighter fit. I was hoping to take measurements of the new covers along with the pictures. Unfortunately my electronic micrometer's battery is dead. I will get the measurements later.

 

At first glance, they looked like they would be a great fit. 

 

 

Upon installing one on a Klixon switch, I thought it was going to be a magic moment.

 

 

They fit okay but I noticed that unlike the original Klixon, once installed, the top of the cover will pull away from the switch. It wasn't enough to fall off, but it clearly was not cinched up like the original cover.

 

 

You can see in these pictures how the cover pulls away from the switch. You can't do that with the original cover. You need to pry the original off. Interestingly, the Shapeway cover doesn't fall off, but it sure looks like it will.

 

 

 

After eyeballing things for a while, it appears the difference is due to a slightly wider (~2mm) tab on the original. 

 

 

I have a busted switch that I will see if I can find a way to glue to top of the cover to keep it on. I will also send the designer a note to see if this can be a little bit wider.

Seems like a version 7 will be needed.

Meanwhile you might be able to use a dab of puddy epoxy to build a little lip on the switch.  That's what I would try.

[carusoam]

They even reproduced the mold sprue mark.  The bump in the center...

Is that causing an unnecessary challenge?

if by chance it is, grind it off...?

Best regards,

-a-

[Marauder]

They even reproduced the mold sprue mark.  The bump in the center...

Is that causing an unnecessary challenge?

if by chance it is, grind it off...?

Best regards,

-a-

I think the mold sprue is actually by design. There is a hole to accommodate it in the switch.

[carusoam]

I get it, that's a locating pin, not a mold sprue.

the original part doesn't show it very well in the photo compared to the more white part.

more photos from the side could help?

Best regards,

-a-

[Marauder]

I get it, that's a locating pin, not a mold sprue.

the original part doesn't show it very well in the photo compared to the more white part.

more photos from the side could help?

Best regards,

-a-

Well, I would have posted more but I couldn't convince the wife to do the photographing while I did the holding. I will post some more pix once I get my micrometer functioning again.

[Hank]

12 hours ago, carusoam said:

They even reproduced the mold sprue mark.  The bump in the center...

Is that causing an unnecessary challenge?

if by chance it is, grind it off...?

Best regards,

-a-

That bump keeps you from putting the cover on upside down, less important with the new blank switch cover than with the old engraved ones. I'd expect these to have been edge-gated; 4 cavities would probably suffice since the early 80s.

[Hank]

15 hours ago, aviatoreb said:

Seems like a version 7 will be needed.

Meanwhile you might be able to use a dab of puddy epoxy to build a little lip on the switch.  That's what I would try.

Looks like,another job for JB Weld!