Scanned or 3D printed mirror covers

Eagle59 said:
I have great news on the cover project. I got my printer and have been playing around with printing the Rocinante as a means of getting to know how the printer works. Bit of a learning curve with that. I used a PLA Carbon Fiber filament and the 9 hour job finished this morning. I printed the right side cover and it came out better that I could have hoped. It fits directly onto the fairing, as is, with no mods or changes. The scan was detailed enough to accurately dimension the three mounting studs. Even the studs for the light subassembly screws are there. The mounting studs work for now but will probably need to be replaced with metal studs for permanent use. I'll try to post the .STL and .3MF files but they are pretty big. The carbon fiber finish is kind of cool by itself. I'm not sure how well the naked finish would handle long term sun and weather. I suppose a clear polyurethane topcoat may help. Fairing, sanding and proper automotive painting processes would be needed for color-matching but the base part came out very well.
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wow, that looks great!
 
No Joy. Getting "...file too large for server..." error. The .3mf file is 14KB, .STL is 53KB. Maybe a DropBox thing?
 
Very nice work! And posting the files for all is very kind of you. Now to see how they print in more weather-hardy materials. I usually use ABS with good success. Only 9 hours to print? That's fast too! I've been working the model to reduce the supports and strengthen the attachment points bc printed pieces are never as strong as molded ones. But to simply have a part in hand is great. Ooh, wonder if the whole housing could be made into a turn signal...cheesy? Lol

Again, awesome work!
 
Glad to contribute. This is only the right side cover but using the mirror function gets you the left side. I'm fiddling around with the infill settings in Slicer to see about changing just the three mounting studs that interface to the fairing clips to 50%. The rest of the cover is the default 15%. The cover is very light but changing the infill on the studs may make that section stronger. I'm just a newbie with this 3D stuff and I know I'm just scratching the surface on what can be done. Lots of good YouTube How-To videos from Bambu Labs on how to modify the print files.
 
I've had good luck with glass filled PET, very strong and reasonably UV resistant. It'll definitely be after being painted...

Plus it's not too difficult to print with.
 
Eagle59 said:
Glad to contribute. This is only the right side cover but using the mirror function gets you the left side. I'm fiddling around with the infill settings in Slicer to see about changing just the three mounting studs that interface to the fairing clips to 50%. The rest of the cover is the default 15%. The cover is very light but changing the infill on the studs may make that section stronger. I'm just a newbie with this 3D stuff and I know I'm just scratching the surface on what can be done. Lots of good YouTube How-To videos from Bambu Labs on how to modify the print files.
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Just make that area solid or increase the wall number to add strength. Sparse infill doesn't offer a ton of strength no matter the settings.
 
Here is the finished product mounted. These covers will go straight onto the bike with only one modification. I had to drill out the holes for the light subassembly. They fit right into the mounting stanchions like they are factory. Even though the studs on the covers are not steel bolts, I think they will hold just fine. They didn't get chewed or damaged after taking them off and putting them on several times. These are much lighter than the factory covers. Even though they have hollow interior sections, they seem to be about a stiff and resistant to flexing than OEM.

When I picked up my bike, it was a salvaged title. The previous owner put 16K miles on it and slid it into a ditch, busting up some of the body work. The saddle bags, front fender, mirror cover(s) and front lower cowl/radiator cover were damaged. They even cracked the clutch cover, repaired with silicone which I replaced long ago. The front fender was a master class in bondo and metal reinforcement. I got a good one from e-bay, cleaned it up and put a carbon fiber wrap on it. The color match of the printed mirror covers is very close to the fender and they compliment each other nicely. I added some black and red pinstipes to the bike to help tie in the black body parts to the factory red. I'm very pleased with the results.
 

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Eagle59 said:
Here is the finished product mounted. These covers will go straight onto the bike with only one modification. I had to drill out the holes for the light subassembly. They fit right into the mounting stanchions like they are factory. Even though the studs on the covers are not steel bolts, I think they will hold just fine. They didn't get chewed or damaged after taking them off and putting them on several times. These are much lighter than the factory covers. Even though they have hollow interior sections, they seem to be about a stiff and resistant to flexing than OEM.

When I picked up my bike, it was a salvaged title. The previous owner put 16K miles on it and slid it into a ditch, busting up some of the body work. The saddle bags, front fender, mirror cover(s) and front lower cowl/radiator cover were damaged. They even cracked the clutch cover, repaired with silicone which I replaced long ago. The front fender was a master class in bondo and metal reinforcement. I got a good one from e-bay, cleaned it up and put a carbon fiber wrap on it. The color match of the printed mirror covers is very close to the fender and they compliment each other nicely. I added some black and red pinstipes to the bike to help tie in the black body parts to the factory red. I'm very pleased with the results.
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It looks great. Very well done!
 
I'd be happy to host these on my Github pages or somewhere else so it is widely accessible. I recently bought an ST1100, with no mirrors, and I'm desperate to get these files!
 
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