My custom toggle switches: Project for base model

[zackmd1]

Anymore progress on this? Waiting to see what the .1mm high resolution print looks like...

Unfortunately no... I discovered an issue with the button mechanism that I want to fix. Problem is solidworks has decided to crash on me and then fail on reinstalation. I have to clean my windows partition on my Mac and then try again. That plus I have been more focused on my exhaust. This week though I will get back to work on the toggles! Expect updates around the middle of the week!

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[zackmd1]

Solidworks back up and running! Hoping to model the redesign tomorrow! The biggest update is the decision to move ahead with a 6061 aluminum material for the toggle itself. Yes the toggle switch will be REAL aluminum as I believe I have figured out the backlight issue.

 

[Rwillis92]

Sweet cannot wait

 

[Asonitez]

Solidworks back up and running! Hoping to model the redesign tomorrow! The biggest update is the decision to move ahead with a 6061 aluminum material for the toggle itself. Yes the toggle switch will be REAL aluminum as I believe I have figured out the backlight issue.

Very nice Zack. I hope to start showing off some of my mods as well. There aren't many but I noticed a huge lack of Tutorials on this forum.

It would seem almost no one knows or has had experience with Katzskin vs Leatherseats.com. I actually found a vendor doing ALL the things leatherseats.com and katzskin does ( the seats are katzskin) but the price is SIGNIFICANTLY Cheaper than other vendors. I worked out a coupon code with them for mustang 6G which brings a 2 Tone Premium Leather including contrast stiching and logo on the seat backs for under 1050. Its only 10 uses though.

Your writeup on the door sills is still the best I've seen.

 

[zackmd1]

Update!!

Revision two of the toggle assembly is done! Ready for test printing. I was able to eliminate one part from my previous version so I am happy about that!

 

[Melekith]

I want to buy this.

 

[The Guardian]

I'm highly interested in a set of these as well.

 

[Stam616]

Nice work! Coming along I see

 

[ConspicuousConsumption]

Very nice Zack. I hope to start showing off some of my mods as well. There aren't many but I noticed a huge lack of Tutorials on this forum.

It would seem almost no one knows or has had experience with Katzskin vs Leatherseats.com. I actually found a vendor doing ALL the things leatherseats.com and katzskin does ( the seats are katzskin) but the price is SIGNIFICANTLY Cheaper than other vendors. I worked out a coupon code with them for mustang 6G which brings a 2 Tone Premium Leather including contrast stiching and logo on the seat backs for under 1050. Its only 10 uses though.

Your writeup on the door sills is still the best I've seen.

Can you link to the door sills thread?

 

[zackmd1]

And version 2 is a success! A few dimensions need to be modified but the design works perfectly and much better then version 1. Closer to a high res ABS print guys!

 

[Rwillis92]

I love it can't wait

 

[FireHive]

What´s the next step? are you gonna test them or do more revisions?

 

[zackmd1]

What´s the next step? are you gonna test them or do more revisions?

Basically the next step is revision 2.1. I need to make the design feasible for machining which means modifying some features and dimensions. After that I plan another test print at a higher resolution and a dry test with that prototype. I might end up doing one more prototype out of SLA just to be sure the dimensions and features work before sending them off to be machined.

 

[ramairgt1]

Nice work but those are going to cost a fortune to machine..even if you have it done in China.
Have you looked into Zinc or aluminum casting? The tooling might be expensive (~2k) but the piece parts will be relatively cheap. You already have alot of built in draft so it shouldn't be difficult to cast. You could then nickel plate them or even hard coat anodize them in pretty much any color.

Edit
You could also look into powdered metal which is even cheaper than casting.

 

[zackmd1]

Nice work but those are going to cost a fortune to machine..even if you have it done in China.
Have you looked into Zinc or aluminum casting? The tooling might be expensive (~2k) but the piece parts will be relatively cheap. You already have alot of built in draft so it shouldn't be difficult to cast. You could then nickel plate them or even hard coat anodize them in pretty much any color.

Edit
You could also look into powdered metal which is even cheaper than casting.

I plan to do the first complete aluminum prototype via machining as I have access to such processes. For a production run I agree that the cost would be crazy. Aluminum casting did come to mind and I would have to do a bit more research on the subject. I am trying to figure out the cheapest way to get 10-20 sets made. That would be for the people interested here. Long term goal is to have an aftermarket company take over the manufacturing and sale.

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