Karter16's Silbergrau E46 M3 Journal

[karter16]

What material is that printed in? I totally get why your dad doesn't like it

What's your plan for the fasteners? Self tappers directly into the plastic?

It's just a regular PLA in forest green, but for some reason ALWAYS prints like that (other PLA's come out lovely). Dad calls it "prototyping green" and is using it up on test prints where it doesn't really matter.

Yep the plan for the fasteners is self tapping screws directly into the plastic. This isn't something that I'm planning on needing to disassemble very often so should be fine in terms of robustness. (unless you have a better suggestion?)

[heinzboehmer]

What material is that printed in? I totally get why your dad doesn't like it

What's your plan for the fasteners? Self tappers directly into the plastic?

[karter16]

Test print of the final SMG bracket design:





I'm really pleased with how this design has turned out. I'll run this for a while and make sure all is well. Hopefully at some point others are keen to give this a go as need to test it with Karb and OE snorkels to make sure clearance is still all good with those.


Also completed assembly test of the Gauge.S enclosure (You can see in the photos why it's Dad's least-favourite filament). Everything fits great thought and I think this is now ready for me to do a final design now that I have the packaging confirmed.

[karter16]

Final version is out for printing!

[Arclitgold]

Does this help in the meantime? https://cad.onshape.com/documents/40...f5b6a01462b639

YES! Thank you Bry5on!

also looking forward to see how yours pans out karter16

[karter16]

Finally! v7467 (exaggerated) is the one!



Now that I've got the placement spot on I'll take those datum planes/points and model up a final clean version.

[Bry5on]

Any chance you’d share the STL of that ash tray insert once it’s done? I’ve been looking to print something similar!

Does this help in the meantime? https://cad.onshape.com/documents/40...f5b6a01462b639

[karter16]

Any chance you'd share the STL of that ash tray insert once it's done? I've been looking to print something similar!

Yep for sure, will be happy to share once I've got it sorted. Worth noting that the version I'm currently working on is for RHD Cars. I could do a LHD one fairly easily, just would need to be mirrored and have the layout of the retainer changed to accommodate the fact the board itself stays the same (ie not mirrored).

Also thought I saw a post here from Avedis but it seems to have disappeared. Anyway, the answer is that I'm planning to measure the size of the tray and cut the insert to fit. Happy to share the measurements once I've got it nailed.


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[Arclitgold]

Any chance you’d share the STL of that ash tray insert once it’s done? I’ve been looking to print something similar!

[karter16]

So I ordered some Alcantara soft today to make myself an insert for the CSL centre console. Shelling out for a genuine one seems excessive so will go the route of making my own. I'm planning to 3D print a template to trace with a blade to cut the piece out.

The other thing that I'm planning to look into on a (literal) rainy day is a script to intercept files coming across FTP from the Gauge.S and to rename them sequentially. One of the issues with Gauge.S is that if it doesn't have the current time from a time server it reverts to an incrementation-based naming convention based on what files already exist on the SD card. This means you end up with a bunch of files named something like GaugeS-1.csv with no easy way to tell which is which. If you happen to be connected to wifi at the time the log starts it's all good. The other way to address this is to use the GPS module to acquire the current time.

I suggested to Sorek that a useful little option would be to store a global variable on the SD card with the current file increment. That way it could persistently assign the next increment, regardless of what files still existed on the SD card. Unfortunately Sorek advised he wouldn't be doing this as he considers it "clutter" and that his solution is to buy the GPS module. Given I have no other need for the GPS module I refuse to use that much hardware to solve such a simple problem so will look to solve this server-side on the FTP server.

[karter16]

Big fillets all around and print it sideways! They're for sure gonna snap if you print it like it's oriented in your screenshot. Printing sideways will make the screw holes super easy to split open, so grab yourself some big washers or maybe open up the holes a bit and press/glue in some metal sleeves.

Could also print at 45 deg for to give strength to both the tabs and screw holes. You'd probably want to model in your own supports though, otherwise you're gonna be printing out an entire forest under that part.

Also, for a second I thought you were gonna gut the small screen radio and design a retainer to hold the Gauge.S inside. Would honestly be pretty cool, but you'd have to figure out what to replace the audio components with. Gauge.S + BlueBus + some custom board to handle I bus commands for the buttons + modern amp stuffed in there sounds neat.

Yeah definitely planning to print sideways. True that it might make the screw holes split, but those ones are thru-holes anyway so hopefully won't be seeing enough load to be split by an M2.6 screw. I figured I'd print this version to test the fitment etc. and then can beef up where I need to for the final print.

Gutting the radio would actually be a really cool project. I'm already running an Xtrons the same as Bryson, but if I wasn't this would be a cool option.

[heinzboehmer]

Big fillets all around and print it sideways! They're for sure gonna snap if you print it like it's oriented in your screenshot. Printing sideways will make the screw holes super easy to split open, so grab yourself some big washers or maybe open up the holes a bit and press/glue in some metal sleeves.

Could also print at 45 deg for to give strength to both the tabs and screw holes. You'd probably want to model in your own supports though, otherwise you're gonna be printing out an entire forest under that part.

Also, for a second I thought you were gonna gut the small screen radio and design a retainer to hold the Gauge.S inside. Would honestly be pretty cool, but you'd have to figure out what to replace the audio components with. Gauge.S + BlueBus + some custom board to handle I bus commands for the buttons + modern amp stuffed in there sounds neat.

[karter16]

Looks very nice! Are you worried about snapping off those little PCBA mounts on the retaining triangular piece? They look pretty fragile.

Yeah I certainly am - as you say they're very tiny. This next prototype will hopefully give me a feel for how much they need to be beefed up. I need them to be flexible enough, but strong enough.


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[Bry5on]

Looks very nice! Are you worried about snapping off those little PCBA mounts on the retaining triangular piece? They look pretty fragile.

[karter16]

Another CAD design project I've been working on has been my own take on the Ashtray insert for the Gauge.S.


Firstly, I wanted to inset the screen at an angle in the same way the displays are on the OE dash components (radio, aircon, etc.). I used the 8385074 radio for inspiration as the screen is not a completely dissimilar size and aspect ratio to the SSD1309 that the Gauge.S uses.





This is what it looks like in Gauge.S ash-tray insert form:



The welcome side-effect of positioning the screen at a slight angle is that it also makes for a less cramped install of the display, and less sharp bending of the ribbon cable.

The screen is held in place by the yellow retainer which I've opted to screw into place. The screws add complexity, however give me better and stronger retention, allowing me to use the other side of the retainer to hold the board. (note the lower left retaining clip is a different shape to the others due to the location of a resistor on the board at that location)





The other significant addition I've made is to add a TE AMP 5 pin header on the back so that the unit is much easier to install and remove.:



The header attaches to a sub-cover which is installed after the display and board are in place allowing for easy assembly. There's enough space underneath the sub-cover for the GPS module (not that I have one), and there is enough space next to the header to put a second one next to it, or indeed 1 larger one if so desired (I am logging everything over CANbus so I only have need of the single 5 pin connector).

I've tested fitted the display into a first prototype of the main body, and have this second prototype out for printing now.