Stock-Style Vapor Speedo Housing

[paniconenvy]

I've been lurking for a while since buying and rebuilding my Hawk, but figured it's time to start sharing....

2 days after getting my plate mounted on the bike, some dude who couldn't see a bright red bike cut me off and I had to lay the bike down. Among the items worse for wear were my speedo and housing, which somehow took an impact and both cracked open pretty badly. After some research, I decided to go with a Vapor but wanted to keep the Hawk styling. Couple that with having a Solidworks license, a 3D printer, and some free time being unable to ride, I decided to experiment.

So this is what I came up with. It's still a work in progress and I fully expect to need to tweak and probably print a few versions, but I think it looks the part. It keeps the stock idiot lights, mounting points, and ignition cutouts. It's two pieces designed to be sandwiched together with a few M4 bolts, and both halves should be printable if I can figure out the correct supports.

Overkill? For sure. More hassle than it's worth? Maybe that too. Absolutely going to work and not be abandoned as a failed idea after I use up 2 rolls of filament? I aim to find out.

[Ziggy]

Excellent idea. I am impressed with the design.
Take into account that the battery for the Vapor has to be replaced periodically and allow reasonable access to the battery in the design.

[paniconenvy]

Thanks!
Good note. Do you know about how often it usually lasts? If it's a yearly (or less frequent) change, it shouldn't be a terrible job to open this up. If it's more than once a season, I'll definitely want easier access

[6]

Very cool. I'm impressed.

Is this something you would be offering to forum members or a one off for you?

[paniconenvy]

I did the design as a personal project, but I'm not opposed to making copies if I can get it to come out looking nice. I have concerns about some areas that I need to prove out before I commit. I'm planning to start the first trial print later today and will update after that finishes.

[Smick6]

Looks awesome. Interested in seeing the outcome.

[paniconenvy]

Hope you guys don't mind waiting to see results. Top half only is estimated at close to 40 hours print time, and these estimates are usually low

[Smick6]

What printer are you using?

[Ziggy]

Thanks!
Good note. Do you know about how often it usually lasts? If it's a yearly (or less frequent) change, it shouldn't be a terrible job to open this up. If it's more than once a season, I'll definitely want easier access

IIRC Vapor recommends replacing the batter yearly.

[skr00zloose]

would you mind sharing the STL (pretty please)? I have zero desire to do any mass production with it or anything, but I have the exact same setup I'm going to mount very soon, and I have designed a laser cut acrylic panel just to get it on for the time being, but the goal was to do....well hell, exactly what you just did.. I have a few printers. (3 fdm and 2 sla, not that I would ever expect an sla part to ever hold up) if nothing else I could give you a point of view of your part fitment on my particular printers.

[paniconenvy]

I have an Ender 3v2. I do have the speeds turned way down, because that's what PETG seems to like best for me. I can probably tune it a bit better, but just haven't printed much PETG yet.

Yearly replacement probably won't be too bad, especially since they might sandbag that number. I may look into adding some easier access anyway if I make these for others.

I won't share the files yet, but mostly because I don't think this design is final. I fully expect to need to tweak some things as I test. If I decide to make to sell, I may try to figure out a way to share the file for a few dollars. Otherwise, I'll be happy to share once it's complete

[paniconenvy]

First test print is going well so far. 18 hours in, a ton to go.

[69Falcon]

Very cool. We have a thread somewhere with CAD files, etc. if you want to share it there.

[paniconenvy]

First half test print is complete and cleaned up. Overall, I think it turned out pretty well for a first try. Some pictures are attached to this post, but check out https://photos.app.goo.gl/CFmoMNC6hejjNTSN7 if you want to see some more detail outside of my 5 photo limit.

Some things I want to try to improve:

• Text is legible but not super crisp. Small text has always been a struggle for my printer, so I need to tune this a bit.
• M4 screw bosses holding in the lights were sized for the cutouts in the stock light housings and the stock hardware. Threading directly into the plastic isn't ideal, but seems to hold well for now. Might try M3 threaded inserts for a more secure hold.
• Surfaces that were printed on supports aren't as clean as I'd like. Most are internal and don't affect anything, so I might leave these as-is.

Some things I'm happy with:

• Fit is excellent. Lenses for the lights have an OEM-quality fit. Vapor cutout might be a hair large, but looks good and allows for float to line up the bolts.
• Threaded insert bosses (for assembly) are sized well and don't interfere with light housings. Lenses need to be placed before housings, but that was expected and is simple to do.

Second half print will be started soon and should be done in just over a day

[Hawk04]

Wow. I'm gonna have to buy a Vapor speedo now.