944 Water Pump Thread Repair

[Tom]

3D-Printer file (.stl) downloadable here:

viewtopic.php?f=20&t=510&p=5045#p5045

[Dare]

I love this! Would have saved me a lot of angst when I was drilling mine by hand.

[four0four]

Gah, I wish I'd thought of this last winter! Makes me want to re-do that work with inserts and this jig...That way I wouldn't have to modify pumps!

What print settings did you use? I imagine it doesn't need to be super overbuilt...

[Tom]

Gah, I wish I'd thought of this last winter! Makes me want to re-do that work with inserts and this jig...That way I wouldn't have to modify pumps!

What print settings did you use? I imagine it doesn't need to be super overbuilt...

I printed it using default CURA settings for ABS (.35mm layer height), but you could print it in just about anything and be fine. No support needed, and no fine details to worry about. As long as your printer is dimensionally accurate, that's all that really matters. (I can print them for Carpokeans who need help too.) You can JB weld the bushings in if they are tight, but I didn't need to on this one...

That RL picture is hard to look at and kind of the extreme reason I opted to make this fixture. With this fixture, you really can't get it wrong. I'd say to post a link to this in that thread to help others, but last I checked RL was still redacting all references to carpokes, so you'd need to post the youtube video or get creative with the link, etc.

[four0four]

Yeah, it was a little rough. I think I'd have been fine and able to center it w/my jig if some PO hadn't helpfully started a hole just off the side of the stud.

Heh, and as far as RL goes: you could probably get away with a redirect, but I'll drop your video in there


re: print settings - perfect, I just got ABS working like a charm, too!

edit: fwiw, this just barely fits in an Ender 3. Had to put it at a funky angle.

[Tom]

Yeah, it was a little rough. I think I'd have been fine and able to center it w/my jig if some PO hadn't helpfully started a hole just off the side of the stud.

Heh, and as far as RL goes: you could probably get away with a redirect, but I'll drop your video in there


re: print settings - perfect, I just got ABS working like a charm, too!

edit: fwiw, this just barely fits in an Ender 3. Had to put it at a funky angle.

I'll split it into 2 halves and post a left and right to make it easier to print on smaller print beds. As long as there are 4 or 5 holes to line it all up, it should work fine....

[four0four]

Some holes for locating pins along the face of the split might be welcome, in case there aren't!

(bah, went to print it yesterday just to have on hand...warped right off. oh well!)

[Tom]

Some holes for locating pins along the face of the split might be welcome, in case there aren't!

(bah, went to print it yesterday just to have on hand...warped right off. oh well!)

I just posted the left and right-side models. They don't fit together, but rather are intended to be used independenly. Depending on which hole you need to fix, you'd just put the appropriate side jig on to fix that hole. I could have just cut it down the middle and added locating pins, etc., but there's no particular point in using both halves to fix any particular hole, and this way I was able to round off the corners to further reduce the chance of warping. Between that and the smaller size, you should be able to avoid warping, even with ABS. For me, an elmers glue stick, hot print bed with PEI, a super tight z-offset, printer enclosure warmed up to 80+F, and a big brim, all combined to avoid warping when printing the full jig in ABS.... But the jig would be just as good in PLA or other easy-printing materials....

[dr bob]

Love the fix!

Any inspiration to heat-cycling the rest of the studs (MAPP gas torch springs to mind) and extracting them now? The next one won't break until you have the engine installed, per my longtime spiritual and vocabulary advisor Dr. Edsel Murphy.

[Tom]

Love the fix!

Any inspiration to heat-cycling the rest of the studs (MAPP gas torch springs to mind) and extracting them now? The next one won't break until you have the engine installed, per my longtime spiritual and vocabulary advisor Dr. Edsel Murphy.

That was an old engine I used as a proof of concept and demo for the tool. A friend of mine once had to do it free-hand with the motor in the car many years ago, and I've been plotting to make this tool every since. Originally, it was going to be a steel fixture but now with 3D printers, the tool is just one download away. If/when I ever rebuild that motor, rest assured all the studs will be replaced....