My FX-R Projector Retrofit Thread

[enildeR]

Frak. That is sexy. FYI, you can go to a autozone (or whatever near you), and they should have a combo DIY gasket kit. Big sheets of cork and rubberised material. They're almost the size of A4 paper. At least something to start with. Just make sure you have some sharp exacto or craft knives to cut them easly. Def look forward to the finished product.

[dude8383]

Popping in again after I saw your post on R3V about these projectors.

Its come a long way and now with 3D printers... this should bring down costs a bit. Are you still planning to make a kit of some sort?

[keflaman]

These SLS parts are super strong. I didn't have an M4x0.7 tap handy, so I just drove the machine screws right into it. The part took the threads fine without splitting or anything. They are flexible and strong (surprisingly so). The material is nylon (sintered powder).

I saw my first 3D printer in action a few months ago. They told me when the parts are finished they wipe them with, or submerge them, in acetone to close the pores up and give it a smooth finish. I mention this because it looks like the parts have a "rough" texture and some dirt on the surface. Did they mention anything like that to you?

[bmwman91]

These SLS parts are super strong. I didn't have an M4x0.7 tap handy, so I just drove the machine screws right into it. The part took the threads fine without splitting or anything. They are flexible and strong (surprisingly so). The material is nylon (sintered powder).

I saw my first 3D printer in action a few months ago. They told me when the parts are finished they wipe them with, or submerge them, in acetone to close the pores up and give it a smooth finish. I mention this because it looks like the parts have a "rough" texture and some dirt on the surface. Did they mention anything like that to you?

They do have a "smooth" option, but I didn't care to pay extra for it. These are ONLY for test fitting things. Once I am 100% satisfied with the fit and alignment, the actual brackets are going to be machined out of aluminum. None of the printable plastics can handle the possible temperatures with 35W+ bulbs in an already-hot under-hood environment, at least not in my opinion.

[keflaman]

Oh, gotcha. Aluminum will be much better.

Carry on.

[bmwman91]

Carrying on I am. The final design tweaks are worked into the CAD model and I am going to see about having the real articles machined. As of now, I am going to try milling them myself since I have a fairly large pile of 7075-T6 material laying around. I tweaked the design a little so that all of the cuts can be made on the manual mill without too much trouble. That will probably happen in a couple of weeks.