How is the long term test on the visor going? Is the nylon working well?
I appreciate the reminder. They have not shown any issues yet. I’ve been focused more on a sunroof rust issue lately. I should pop them off and see if any cracking exists etc.
So I turns out I had my own 3d printed nylon one in the whole time. It worked great, but it just looks horrible.
The issue why I didn’t install the new professionally-done nylon ones yet was because apparently I was off by 1mm and they didn’t sit low enough on the bar, which prevented the retaining spring and the star lock washer from being used. This was why I was trying to figure out a new method to lock that part on i.e. the shaft collar + screw.
[[I never followed up on the star lock washer – it was too big. I cannot find a star lock washer that matches OEM dimensions. ]] Geez that was NOVEMBER. I need to really start posting small updates so I’m not re-doing work that I forgot. My age (and lack of available time) is showing.
This seems to work quite well. It needs some tweaks but seems to work just as well as the spring + lock washer combo. Once I make those tweaks I’ll install them and see how they function.
It looks like the shaft has wear or damage, could it be that the star washers you have are the correct size but the shaft size has changed? I think the spring and star washer is going to be a better long term solution. It maintains constant pressure and self adjusts if/when the plastic wears a bit.
It’s a fair critique.
I just cannot find a star lock washer that matches oem, mainly with the outer diameter.
Oh, I didn’t realize that a specific outer diameter was important for this application.
Yeah if it’s bigger than 13mm it won’t fit in the hole in the ceiling.
I’ve bought 3 types of lock washers and they’re all either too big or too small. It’s so crazy. That’s pretty much the only thing holding me up from finishing this design.
SOME SUCCESS! I found a clip that works! The E-clip dimension is rare.
I’m going to add these clips with the rubber washer on the nylon parts and see how they fare. If this works, I’ll consider the part issue solved. I want to re-create the sun visor too but I think the mounting problem was the biggest hurdle.
Just a side note, I hated the star lock washer design because it required a lot of downward force for it to lock on, which in turn actually damages the visor itself (i.e. trying to push/hammer the thing on). So this clip/lock that attaches from the side with some needle-nose pliers was the better option to save a perfectly functional visor. I also felt the OEM spring wasn’t necessary if you can lock the rubber washer down with the mount, but we’ll see once everything is installed.
So far so good after about 10 days’ use.