As shown in the What did you do to your Volvo today?-Thread I have designed a repair patch for the center tab of the dashboard kickpanel on the drivers side.
What is the Issue?
The mounting tab where the kickpanel is held in place by a torx screw breaks/crumbles off and the screw has nothing to hold onto anymore. Repairing this is hard because the mounting surface sits at an angle with respect to the surface of the kickpanel.
A broken tab looks something like this:
- PXL_20240325_215746302.jpg (127.9 KiB) Viewed 1762 times
- PXL_20240325_215722152.jpg (255.11 KiB) Viewed 1762 times
What is the Solution?
I designed a small repair patch in Fusion 360 that reconstructs the original mounting tab and has a wide brim which acts as a glue surface, bonding the repair patch permanently to the kickpanel. As you can see in the screenshots, it follows the curvature of the panel as well.
- Screenshot 2024-03-26 012611.png (213.21 KiB) Viewed 1762 times
- Screenshot 2024-03-26 012624.png (27.19 KiB) Viewed 1762 times
This little repair patch can be 3D printed, either on your own 3D printer, with a commercial printing service or perhaps a friendly forum member (who hopefully does not have ambitions to make big money with it
)
- PXL_20240325_234820544.MP.jpg (426.29 KiB) Viewed 1762 times
The patch is glued in place with plastic glue. It is important that the glue can bridge small gaps, so the use of a thicker glue which has some filler material is preferred. Normal CA super glue might not give you the best results but I have not tested it yet.
Clamp it firmly until the glue is dried. The clamp can damage the vinyl cover material, so use some towels as a protection.
- PXL_20240326_202321969.jpg (217.36 KiB) Viewed 1762 times
This is how the final result should look like and fit in the car:
- PXL_20240325_235226669.jpg (246.15 KiB) Viewed 1762 times
- PXL_20240326_203712240.jpg (304.03 KiB) Viewed 1762 times
- PXL_20240326_203824231.jpg (304.49 KiB) Viewed 1762 times
- PXL_20240326_203810377.jpg (258.78 KiB) Viewed 1762 times
Why is it green?
Because that's the color I had on my printer for the prototype and it makes it easy to distinguish on photos. You can print your patch in any color you'd like, preferrably a dark grey or black so you won't notice the patch.
How can I get a Repair Patch?
The model files of the repair patch are published on Printables: https://www.printables.com/model/820589 ... pair-patch under a Creative Commons CC-BY-SA License. This means that you can use and publish the files freely, but you have to mention my name as the model origin. You are allowed to modify it, but you have to share it under the same license and conditions.
You are allowed to use it commercially, but if you're making a lot of money with it, please give some back to the original author (me). Stuff like that takes time, filament and money.
Generally you have multiple options to get a repair patch:
1) You have a 3D printer and want to print it yourself.
2) If you live in Germany or Europe, I can send you one for a little more than shipping cost.
3) You know someone who has a 3D printer and can print it for you.
4) Perhaps someone in the forum locally to you wants to print one for you.
5) Use a commercial 3D printing service like Shapeways (expect cost of around 5-10€/piece + VAT + shipping).
If you have an account on Printables (or want to create one) please leave a like and post a Make. This gives me Prusameters, which I can redeem for filament. It doesn't cost you anything
Disclaimer
So far I have only tested it on one kickpanel of my car. I don't know how the tolerances are between panels and if they fit all model years.
Tested so far is my 1998 Volvo V70I. I am open for suggestions and feedback, but please stay constructive and friendly.
This goes without saying, but... if you destroy your kickpanel or glue your fingers together, it is your risk.
Have fun and best regards,
Chris
