Replacement 3D printed main relay box covers

[Gromit]

I just noticed this new "Technical stuff" category.

Thought I would re-post a previous thread in it that I started back in 2024 in the "Electrical" section .

https://lanciabeta.co.uk/forum/index.php?topic=5165.msg37616#msg37616

It might rekindle interest in another 3D project....replacement relay box covers in the Beta engine bay which inevitably disintegrate with time and engine bay heat especially given the relay box location above the exhaust manifold!

Second hand replacements in good condition are hard to find and notoriously overpriced.

Andrew

[JASPER_40]

Hi Andrew,

I think the relay/fuse box would be a major league 3d printing challenge and I am not sure about the longevity of 3d printed item printed with the most resilient plastics type (ABS) as it is directly above the exhaust manifold…. As you said

I printed a multi plug to replace one that had started to burn because of a failing high resistance joint (radiator fan connection). That print was hard to get right and so the whole fuse box would be really tough.

I would advocate that one should regularly clean and lubricate all connections as a preventative measure.


Cheers

Steve

[Gromit]

Steve,

Just to be clear, I was referring to the clear fuse box cover as per the photo in the link in my post above to the original posted topic, not the whole fuse box. Original topic thread link reproduced here again:

https://lanciabeta.co.uk/forum/index.php?topic=5165.msg37616#msg37616

My 3D printed fuse box cover was sourced from a guy with a 3-D printing business in the USA, (who prints rare and in demand classic car parts on the side as a hobby), which I bought on ebay is holding up ok so far and is certainly better than the disintegrated old one!

I have wrapped some aluminium foil tape around the outside edge of the fuse box cover as token heat reflection attempt. I was planning to install a reflective and protective heat shield above the exhaust manifold. Purchased the heat shield material but have not done anything about getting it fabricated and fitted.

By the way Steve, many thanks for posting the photo of the disassembled Beta rear brake caliper parts in my thread on a dodgy Beta hand brake problem. Very helpful and a useful future reference for anyone who needs to do a rear caliper overhaul or repair.

Cheers,
Andrew

[Joe912/62]

I have 3d printed one in black with white symbols to replace my broken one.
Can easily be printed in clear also. I’ll post a picture later.

[Joe912/62]

Photo

[JASPER_40]

Blimey Joe….. brilliant … next level

Do you use parametric design to create from scratch or use a scanner ?

What design package do you use ?

Cheers

Steve

[Joe912/62]

Basically From scratch, Fusion 360 a bit of AutoCAD
 and Coreldeaw.

[peteracs]

I have 3d printed one in black with white symbols to replace my broken one.
Can easily be printed in clear also. I’ll post a picture later.

That is a really neat solution having the legends like that, very nicely done. What material did you use?

Peter

[Gromit]

Agreed. It is better looking than the clear 3D printed version that I purchased from a 3D printing US ebay seller.

The 3D printed "clear" version was more of a translucent slightly textured finish which must have been based on a scanned sample as it showed up a few imperfections from the scanned master.

Definitely the 3D version benchmark for a main fuse box cover Joe!

[WestonE]

Amazing work. The reason for a clear cover is to see at a glance if fuses have blown. If that does not matter to you or you will simply take the cover off no issue.

[Ferrit]

that is cool.  WD :-)

All you guys and your 3d printing need to set up a shop front :-)

Mark

[Nigel]

Joe, I really like the black fuse cover.

If it becomes available count me in!

Nigel

[peteracs]

Hi Joe

Looking at the photo, am I correct in thinking the white legends are raised above the main black case, so that you print the case and then assuming no multi filament system is available, you pause the print job, change filament colour and resume, thus printing the legends?

Peter

[Joe912/62]

Yes the white is raised but I have a AMS for multi color filament, but you can do it that way also.
I’m going to print it with the white incorporated in the black filament. If someone is interested I can provide one for them to try.