New part available: Intermediate Housing PN 64501811407 replacement

[x_atlas0]

Howdy, everyone!

Over the last few months, after the success of the fuel cap holders, (feel free to drop me a PM if anyone wants one, I can make more) I decided to make another part, this time something very difficult to find in decent condition. As some of you may know, I've been slowly gathering the parts to upgrade my car to have AC, but I was having a very hard time finding this part that connects the AC system to the heater ducts:

So, after asking around, @sfdon come through and let me borrow an example for a while. I used that part, and the pieces I had around, to develop my own, custom design. I went through several iterations to improve the design, based on feedback from @sfdon. This new part is a direct replacement, but is substantially more robust than the original. @sfdon verified that it fits via his shop.

I make each one at home, and they take me quite some time to make due to their size. After the first few orders, I plan to use the proceeds to buy a bigger 3D printer so I can make the thing in fewer sections, if not one piece.

If there's enough interest, I also have the original equivalent part for the E3, which has side exits. I can model and print that up too, but I'll need to work on the CAD. I can also use the info I have to make the non-AC version if people want.

Given the size, material cost, and print time involved, I'm asking $400 USD for one of these units. I have 2 printed, ready to go right now.

Please let me know if anyone would like one via the thread or PM!

Thanks,
Matt

 

[x_atlas0]

Any feedback from the group? I know this isn't a common part to need (unless you are doing a resto) but I'd like to know if the board wants me to keep making some new parts like this.

 

[deQuincey]

sadly i find not a lot of feedback in the group, but we have a lot of new requests and questions

your work @x_atlas0 is exceptional
very difficult to find part
well done,

you will save a life or more, for sure, but they yet still dont know

 

[rsporsche]

Matt ... i have added this part to the FAQ - Best Sources thread under 'specialty parts'

 

[x_atlas0]

As mentioned in other threads, I also have a custom-designed version of the side grilles (these:

) so if someone wants to try them out, let me know.

 

[rsporsche]

hi Matt, do you have a pic of the custom grilles? i would be interested as the ones i have are actually the 'cut' ones for an e3. i have added you to the Best Sources FAQ under specialty parts

 

[x_atlas0]

Howdy, @rsporsche here's where I've put these pics up so far: https://e9coupe.com/forum/threads/m...l-and-gas-cap-holder.41537/page-2#post-381191

Original on the left, mine on the right.

The ends are cut off because my printer isn't big enough. After I get some more parts sold, I can snag a bigger printer and correct the limitations.

I verified these fit using the new panels from @aguirola.

 

[rsporsche]

i actually like the smooth panel more than the factory textured piece. the vinyl on the console is pretty smooth - perhaps painting them with SEM colorcoat and lightly texturing the wet paint might work

so what do you want for a set?

 

[x_atlas0]

@rsporsche I would like to get some external feedback first, I've only made a few trial sets. So if someone wants to try them out, please PM me.

Off the cuff, each one takes me between 10-24hrs to print, plus a significant chunk of a spool, depending on how pronounced people want the layer lines.