Honda Insight Forum banner

1 - 20 of 107 Posts

·
Linsight Designer
Joined
·
1,877 Posts
Discussion Starter #1 (Edited)
Tired of that broken driver's side window switch?
Why not print your own replacement switch parts?
The files are open source (with attribution):
View attachment Insight Window Switch.zip

I initially offered these for sale, but have stopped for three reasons:
-Lack of demand; I've only sold a handful of units.
-I'm not making enough to make it worth my trouble at this low volume.
-Too much customer support. Yes, the dashboard has to come out ;)... Yes, there's a thread on how to do that. No, I won't walk you through it on the phone. *ahem*.

I stand behind the product I've already shipped, and will warrant those units in the field, if needed; to date, I haven't had a single return for any 3D printed part I offer.

Here's how to install:
There are two design defects in the driver's side window switch:
Spring Detent Body: Terribly designed... I imagine this and the trunk latch mechanism were designed by the same intern.
[/url]
The new design is mechanically superior.
-Body thickness increased 30%
-Added a foot that extends down to the PCB; operating the switch now compresses the body, whereas the OEM design experienced shear force (an order of magnitude weaker).

Light Pipe: Also the mechanical linkage that interfaces with the electrical switch.
OEM part is decently designed, except that a light pipe is too brittle to use as a lever, particularly without a hard mechanical stop. The new part is opaque, so the switch will no longer light up at night; VeroClear is the only strong enough clear material and it's only available on high end PolyJet machines... if there's enough demand, we could do a group buy.

Kudos to user Element6 for sending me his broken window switch. Mine isn't actually broken, but I figure this is a fairly common failure that needs fixing.

If you're not comfortable opening up your broken window switch, PM me and we can arrange to ship your entire unit to me; I'll fix it and send it back for $45 (including return shipping CONUS).

Note the feel with 3D printed parts feels softer than OEM - but is still tactile - due to the layering method used in 3D printing. A PolyJet print (group buy) would feel more like OEM, but would also be more expensive.

*You'll likely need a high end 3D printer to resolve these small, dimensionally precise parts. I'm printing drop-in ABS parts on a $30,000 Stratasys SST, but I imagine any machine over $3000 will do a decent job with just a bit of sanding. FYI: Parts printed in PLA won't hold up to the heat/UV.
 

·
Registered
Joined
·
3,233 Posts
What exactly does this repair? My switch works but doesn't always return to the center off position when I release it. I suspect it causes the circuit breaker to trip since it's activating the motor continuously until I manually center it, and then have to wait a few minutes for the window to work again. Will this part fix that problem?
 

·
Registered
Joined
·
3,233 Posts
That's why I asked what does this fix? And what does $25 shipped CONUS mean? I know FedEx, UPS, DHL, Purolator but never heard of CONUS.
 

·
Hypermiler
Joined
·
3,650 Posts
CONtinental United States. Probably more $ shipping for UK and such.

(reviewing video again, will repost soon)

At about 2 min or 2:10 in mudders' video, the smaller piece seems to break 1st, which cause too much force to be applied to the larger piece which will break next, rendering the switch inoperative.
 

·
Moderator
Joined
·
3,641 Posts

·
Linsight Designer
Joined
·
1,877 Posts
Discussion Starter #10
That's why I asked what does this fix?
This fixes the common 'limp' master window switch problem, i.e. the driver's side window switch doesn't return to neutral and flops around. There are two parts that break due to poor design; replacement parts are superior design.
 

·
Registered
Joined
·
3,233 Posts
Just got around to starting this fix and have the switch apart. Looking at the two pieces that were sent (in the middle of the picture) they don't look anything like what is shown in the video. Obviously they don't fit like they are supposed to in the video. Did you send the wrong parts by chance? My dash is apart and the windows are down and they are calling for thunderstorms soon. ARRGH!

 

·
Linsight Designer
Joined
·
1,877 Posts
Discussion Starter #14 (Edited)
Did you send the wrong parts by chance?
Yes, that is certainly the trunk latch parts. Apologies on sending the wrong parts. I ship around 10 trunk latches per week and thus far have only had two window switch orders. I'll overnight the window switch parts as soon as they finish printing tonight. Keep the trunk latches. You can certainly roll the windows up by just moving the switch lever on the PCB. My mistake. I've also refunded your entire purchase price.
 

·
Premium Member
2001 5S "Turbo"
Joined
·
10,579 Posts
Now that (Mudder) is excellent service and dedication to the INSIGHT community.

Willie
 

·
Linsight Designer
Joined
·
1,877 Posts
Discussion Starter #17
Now that (Mudder) is excellent service and dedication to the INSIGHT community.

Willie
Thanks for recognizing my commitment to service! In this case, I dropped the ball and felt bad our fellow Insighter's car was put out of service due to my negligence.

The part ended up shipping 2-day because I missed the guaranteed 1-day time (11AM), but not the guaranteed 2-day time (e.g. either way it will still get there Saturday).
 

·
Registered
Joined
·
3,233 Posts
Got it today and have it installed. Works great thanks. Good chance to clean the instrument cluster since the trim is off too. Looks like glass now.
 

·
Where's the hammer?
Joined
·
49 Posts
D'oh!

My dash-mount window switch lever broke - for the passenger window!

Just bought a new part and put it in.... probably a similar fate as the driver lever.

Threw it into the box of old replaced parts........

Thor
 

·
Linsight Designer
Joined
·
1,877 Posts
Discussion Starter #20
D'oh!

My dash-mount window switch lever broke - for the passenger window!

Just bought a new part and put it in.... probably a similar fate as the driver lever.

Threw it into the box of old replaced parts........

Thor
The passenger window switch should be much harder to break because it has a mechanical stop designed into it, preventing excess pressure on the switch. If the passenger switch broke, I imagine the switch got hit hard. I'd love to take a look at your broken switch to see if there's a hidden design defect; could benefit the Insight community ;). PM me your paypal address and I'll cover the shipping... I'll ship the part back when you're done if you'd like it back.
-John
 
1 - 20 of 107 Posts
Top