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CAD/CAM drawings for Syncro diff lock console
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WestyWonderland
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PostPosted: Fri Nov 15, 2019 5:00 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

beach_creature wrote:
Check this out.

https://smallcar.com/vanagon/vanagon-direct-replacement-parts/differential-lock-light-panel.html


Small car was my second guess lulz

It's a very high quality board. It would not be hard to make with an etching kit.
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WestyWonderland
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PostPosted: Fri Nov 15, 2019 5:03 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

SyncroChrick wrote:
We are on a parallel path...I just had my friend printed one this week. He just sent me some pictures. He is making another one now in black.

Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

Looks good. What material is used?
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PostPosted: Fri Nov 15, 2019 5:10 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Before you go to too much trouble check out this second cad/cam file. It has the countersinks for the knobs and I think better fit all round. I had one made, en route today and will review it here when it's delivered.

https://www.thingiverse.com/thing:3239575



SyncroChrick wrote:
An update on my side too. I spoke to my friend today and he thinks the type of plastic he was going to use may not be resistant enough in the heat. So he will try something else.

He also noticed the imperfection and apparently something not complete in the diagram, so I am going to send him my existing console next week. He is going to improve the CAD drawing, in the hope of getting a version even closer to the original one. I trust him on that, he is very nerdy and perfectionist. I am really hopeful.

The metal bracket should be fairly easy, I have a friend in Quebec who could probably do it.

Now on the other hand, I have no idea yet how to replicate the circuit and especially the plastic visible piece with the 4 wheels and the 3 green lights (not sure how to call it).

Any suggestion?
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livethevanlife
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PostPosted: Fri Nov 15, 2019 9:09 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

This is really cool stuff and has me wondering what other hard to find bits we can print for our vans. I know you can search Thingverse and there are a decent selection of files for download, but would be great if we had a public vanagon 3d printer file repository and request list.
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WestyWonderland
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PostPosted: Fri Nov 15, 2019 11:20 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

That is a good idea
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PostPosted: Fri Nov 15, 2019 11:32 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

If there is interest id be happy to host them on my website www.livethevanlife.com, non commercial im not looking for any money or profit from it.
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PostPosted: Fri Nov 15, 2019 12:54 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

What about the stand-offs for the circuit board and the front locker lockout?
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jkidd152
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PostPosted: Fri Nov 15, 2019 6:18 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Got mine today!


Image may have been reduced in size. Click image to view fullscreen.


Image may have been reduced in size. Click image to view fullscreen.

This is from the other cad file mentioned above.

Thingiverse File number 3239575

The fit seems really good. Iíll post more once I get it mounted
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SyncroChrick
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PostPosted: Fri Nov 15, 2019 6:57 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Looks great. Do you know what kind of plastic was used? or was it ABS?
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PostPosted: Fri Nov 15, 2019 7:04 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Jkidd -- that's pretty well designed and needs only finishing work. I especially like how the designer handled the LEDs although a glowy display has an appeal all its own.

With any luck my replicated unit shows up tomorrow and I can get the rear locker working. Then it's time to install a front locker and quaiffe in the back.
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PostPosted: Mon Nov 18, 2019 3:32 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Got my second console today. It was made from this CAD/CAM file

https://www.thingiverse.com/thing:3239575

This one is markedly better than the other design. No comparison!

This unit seems to be made directly by craftcloud in Munich. I chose MJF nylon and the delivered price was $72.

The print quality is Syncro worthy sturdy, thick, heavy and may not strictly require a metal bracket. The finish is GOOD. NO FINISHING NEEDED!

The photos posted by other owners are what you'll get. My pictures are hard to see for the flat black finish but you can see it's ready to install !
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.

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jkidd152
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PostPosted: Mon Nov 18, 2019 3:46 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Wow, great choice to go with the Nylon! Looks great. Mine is ABS plastic and I need to sand out the imperfections. I also need to paint mine brown...

What are your plans/ideas for the decal image above the knobs?
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PostPosted: Mon Nov 18, 2019 3:55 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

The description of material quality is really valuable. We could make a comparison chart.

The same file used to make this includes a good drawing of the graphic. Ill run one off at home but will get one of the decal suppliers to print one on automotive grade material. If it's thick enough, guessing 12 mils or so, it should apply cleanly. A thinner decal would need a smoother surface, involving sanding/polishing.
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PostPosted: Mon Nov 18, 2019 7:19 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Totally awesome , I'm very impressed , keep up the great work guys Applause
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PostPosted: Tue Nov 19, 2019 9:08 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Funny how none of the designers added the Syncro diagram graphic to the part itself as an embossed image, then the raised figure can just have paint rolled over it. Or depressed so the lines can be filled with a paint pen. I would have done one of those (that is, if I wanted dash knobs, which I don't. I'm using Redshiftt)

There's such a difference in finish quality, too, depending on how long you're willing to let the part take. Some of those parts really look like crap. The last one is pretty good, but probably took three times as long to print. I dunno, maybe some of the slicer programs allow changing print specs for different areas of a part, the one I have has a lot of settings, but the things that determine finish quality are global.
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PostPosted: Tue Nov 19, 2019 9:30 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

I would have done one of those (that is, if I wanted dash knobs, which I don't. I'm using Redshiftt)

Just read the info on Redshift , looks like a good concept and look forward to seeing it out on the market.
I always thought a Morse cable would be a simple none techie way to go too but routing the cable may prove to be difficult.
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PostPosted: Tue Nov 19, 2019 9:55 am    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Thanks for taking a look, Burl. I'm working on finishing up the design of the relay and solenoid valve enclosures and I can get it on the market. Ready-made enclosures are expensive and none of the sizes are quite right, and it's been a challenge to come up with a weathertight design I can get made cheaply. I'm close, but life and the need to make a living keep getting in the way, or I would have been selling this last year. Maybe we can get an advance copy in your hands to try out and get your feedback.

Yeah, running a Morse cable front to back could get tricky, it wouldn't be an easy thing for a DIY-er. I did work up a setup using a short one worked by an electric screw jack in the engine bay, it didn't work that great, and you need to have a dual-action spring coupler inline. Not hard to make, but it's another component to manufacture, whereas using air, whether vacuum or positive pressure, the air acts as the spring both directions for free. So I'm using positive pressure, and the pneumatic components are ready-made, cheap and good quality.
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PostPosted: Tue Nov 19, 2019 12:52 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

tencentlife wrote:
Thanks for taking a look, Burl. I'm working on finishing up the design of the relay and solenoid valve enclosures and I can get it on the market. Ready-made enclosures are expensive and none of the sizes are quite right, and it's been a challenge to come up with a weathertight design I can get made cheaply. I'm close, but life and the need to make a living keep getting in the way, or I would have been selling this last year. Maybe we can get an advance copy in your hands to try out and get your feedback.

Yeah, running a Morse cable front to back could get tricky, it wouldn't be an easy thing for a DIY-er. I did work up a setup using a short one worked by an electric screw jack in the engine bay, it didn't work that great, and you need to have a dual-action spring coupler inline. Not hard to make, but it's another component to manufacture, whereas using air, whether vacuum or positive pressure, the air acts as the spring both directions for free. So I'm using positive pressure, and the pneumatic components are ready-made, cheap and good quality.


Chris , I totally agree with you and think your design is the way to go !
Those old Mercedes vacuum door lock actuators were a bad design from the get go back when MBZ did it in the 70's ,why Puch would put it on a diff locker is beyond me LOL
I'd be happy to offer feed back as well as help in way that I can Very Happy
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PostPosted: Thu Nov 21, 2019 2:47 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

Quote:
Those old Mercedes vacuum door lock actuators were a bad design from the get go back when MBZ did it in the 70's ,why Puch would put it on a diff locker is beyond me LOL


I think it was the same reason German OEM's in general started using vac to do little jobs like door locks and vent control flaps: it's real cheap, lightweight, nearly silent, and the power source is basically free. Snap-together plastic parts and little valves can be made in the millions for nearly nothing, the same parts can be used in lots of platforms, plastic tubing and short bits of rubber hose are way cheaper than lots of copper wire, and easier to assemble. I think Steyr/Puch just went with the flow, so to speak, no doubt prodded along by VW's bean-counters. It's fine for those other uses, but it sure is a lame way to do the diff locks. Try getting one to engage at 12000ft. up in Colorado, when you might have 6"Hg. available if you're lucky. You'll be waiting a long time if it ever drops in at all.
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PostPosted: Thu Nov 21, 2019 5:40 pm    Post subject: Re: CAD/CAM drawings for Syncro diff lock console Reply with quote

[/quote] I think it was the same reason German OEM's in general started using vac to do little jobs like door locks and vent control flaps: it's real cheap.

Good point , not sure why I didn't see this obvious answer lol
Yep ,Gotta love it......... total crap product but it is cheap...... oh but wait the price of the Mercedes is not cheap ..........what happened ??? Hahahahaha.
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