New Klixon switch covers

[AH-1 Cobra Pilot]

15 minutes ago, Buckster said:

Looking to buy the "Push On Low Boost" for a buddy who has a M20J. Please let me know how I can obtain this from you.  Thanks, Den

I just sold my last LOW BOOST, but I will be making more in the next month or so.  I will PM you when they are ready.

[PT20J]

20 minutes ago, AH-1 Cobra Pilot said:

I just sold my last LOW BOOST, but I will be making more in the next month or so.  I will PM you when they are ready.

Are you set up to also make the ETA covers now?

[AH-1 Cobra Pilot]

13 minutes ago, PT20J said:

Are you set up to also make the ETA covers now?

Yes.  I got an STL file that I can print from another MSer.  I have no way to test the fit and, because of this, cannot modify the file, so I trust the design is good.  I have successfully printed some and will be painting and laser etching them soon.  Let me know what letterings you would like.  I will start with the standard:

NAV LITE
LDG LITE
STROBE LITE
ELEV TRIM
BOOST PUMP
PITOT HEAT
AV MASTER

What else?

[JayMatt]

@AH-1 Cobra Pilot are you making those air vent covers too by chance? Can you? 

[AH-1 Cobra Pilot]

1 minute ago, JayMatt said:

@AH-1 Cobra Pilot are you making those air vent covers too by chance? Can you? 

Yes.  I have been working on two different approaches:  A direct replacement of the vent cover, and something to hold an 'eyeball' vent. 

I have a really good substitute for the cover, although it is best if you paint them, and you have the PITA of removing the rest of the overhead plastic to get them in place.  They are tough to print because of the geometry of the part, which makes them prone to delamination and cracking in the printing process.  Once treated, they are pretty stable.  Painting adds strength, as well.  This is the less expensive option, as the eyeball vents alone costs 2-3 times what these will.

The eyeball mounts are much worse, as far as delamination and cracking goes.  The shape makes them really hard to print well in ABS.  I have made some in nylon, but that is hard to paint and much more expensive.  I can also make them in carbon-fiber infused PETG, which should be very stable and easier to print, but not as receptive to paint.  The great thing about them is they can be very easily installed.  (Well, at least you do not have to remove/replace anything else.  It is still a PITA to get the hardware in there, up there!)  I installed one in my Mooney and am still evaluating it.

Please let me know here if you are interested in either.

 

[Barzook]

On 4/11/2023 at 10:58 PM, AH-1 Cobra Pilot said:

Yes, I am making more switch covers!  This time both Klixon and ETAs.  If anyone needs non-standard letterings, let me know.  Anyone who wants ETA covers, PM me with what you want, so I know what to laser etch.  I should have some ready to ship in May, if not earlier.

I have a 1977 M20J with a broker Boost Pump cover. Not sure if they are ETA or Klixon though.

[AH-1 Cobra Pilot]

50 minutes ago, Barzook said:

I have a 1977 M20J with a broker Boost Pump cover. Not sure if they are ETA or Klixon though.

Look at the back.  This is a Klixon.

ETAs have what looks like four pillars with bridges across the tops.

[JayMatt]

18 hours ago, AH-1 Cobra Pilot said:

Yes.  I have been working on two different approaches:  A direct replacement of the vent cover, and something to hold an 'eyeball' vent. 

I have a really good substitute for the cover, although it is best if you paint them, and you have the PITA of removing the rest of the overhead plastic to get them in place.  They are tough to print because of the geometry of the part, which makes them prone to delamination and cracking in the printing process.  Once treated, they are pretty stable.  Painting adds strength, as well.  This is the less expensive option, as the eyeball vents alone costs 2-3 times what these will.

The eyeball mounts are much worse, as far as delamination and cracking goes.  The shape makes them really hard to print well in ABS.  I have made some in nylon, but that is hard to paint and much more expensive.  I can also make them in carbon-fiber infused PETG, which should be very stable and easier to print, but not as receptive to paint.  The great thing about them is they can be very easily installed.  (Well, at least you do not have to remove/replace anything else.  It is still a PITA to get the hardware in there, up there!)  I installed one in my Mooney and am still evaluating it.

Please let me know here if you are interested in either.

 

The ones with the eyeballs. Carbon fiber. What the cost on those? That's what I want because imo those better direct the airflow right?

[ttflyer]

On 4/18/2023 at 1:11 PM, AH-1 Cobra Pilot said:

Yes.  I got an STL file that I can print from another MSer.  I have no way to test the fit and, because of this, cannot modify the file, so I trust the design is good.  I have successfully printed some and will be painting and laser etching them soon.  Let me know what letterings you would like.  I will start with the standard:

NAV LITE
LDG LITE
STROBE LITE
ELEV TRIM
BOOST PUMP
PITOT HEAT
AV MASTER

What else?

We could use RECOG LITE in addition to those mentioned.

 

We are re-doing our panel in a few months and could use a fresh set of switch covers.  Our installer seems to want to stick with stock rather then a different style switch...

 

[PeteMc]

@Cobra Pilot I may need a couple of replacements soon.  Did you get the printer heat increased or make any other changes to keep the layers from separating?

 

[AH-1 Cobra Pilot]

1 hour ago, PeteMc said:

@Cobra Pilot I may need a couple of replacements soon.  Did you get the printer heat increased or make any other changes to keep the layers from separating?

 

If you want the vent covers, I will try making you four of them and let you know when they’re done.  You will have to paint them with an acetone-based spray paint, as that makes them stronger.  They are a direct replacement for the old ones.

If you want the eyeball mounts made from PETG, I can probably make them in the next week or two. (I will have to greatly modify the design to make them from ABS.) Depending on the color you want, you might have to become my painting expert, since I have not done much painting of PETG.  I can also make them from glass or carbon fiber infused PETG, which will make them stiffer and stronger, but the plastic filament costs 2-3 times as much, and limits the color choices.

[PeteMc]

5 hours ago, AH-1 Cobra Pilot said:

If you want the vent covers,

Sorry, I was referring to the switch covers, not the vents.

[AH-1 Cobra Pilot]

1 hour ago, PeteMc said:

Sorry, I was referring to the switch covers, not the vents.

The switch covers are great.  I will have some ready soon.

[Tmack201]

AH-1 Cobra Pilot, have you made any covers for ETA switches yet?
Trying to replace Strobe Lite cover.

 

[AH-1 Cobra Pilot]

1 hour ago, Tmack201 said:

AH-1 Cobra Pilot, have you made any covers for ETA switches yet?
Trying to replace Strobe Lite cover.

 

The ETAs are much more difficult than the Klixons.  I am still working on them.

[Tmack201]

Thanks, AH-1, let us know when you start producing as I’m sure there’s a lot of interest out there!

[carguy4471]

@AH-1 Cobra Pilot Any chance you have a High Boost / Low Boost switch for a Klixon?

[AH-1 Cobra Pilot]

On 4/19/2024 at 8:14 PM, carguy4471 said:

@AH-1 Cobra Pilot Any chance you have a High Boost / Low Boost switch for a Klixon?

Why yes I do.