In follow up on a frame damage as per the DAMAGE REPORT article, we had to do few improvements. One of the obvious problem has been that forces were not properly transferring from the upper part of the frame to the suspension – causing major stress on both upper and lower clamps. While that looks like an obvious design flaw, it’s been caused by a late decision to actually add the suspension (& wheels) itself.
Anyway, a new clamp was needed to address this. See the image compare widgets below. The first one shows whole gondola with a new clamp, where second one comes with an detail.
Second image compare also shows material reinforcements to the front clamp, where new reinforcing rings were introduced to improve clamp’s strength.
Printing both took a while as there were still some problems with a printer’s filament feed & flow settings, but finally had everything working out with following setting in Cura.
Prints worked out very well.
Interestingly whole clamp worked out to be weighing 107g.
Then mounted with tubes it looks pretty cool.
Final part was to fix one of the tubes which broke.
Procedure itself was already tested, but I’ve been still glad it worked out again. Simply wrap it in additional two layers of CF, apply resin, another layer of “white tape” followed by a layer of the office tape and finally heat it up with a fan to 160C for 20 minutes.
It worked out nicely and it feels strong again!
Next step is to continue with mounting new clamps so we are ready for another taxiing test! I plan to add few more pics on that (finalized clamps installation) later.
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