Firebrid: The Prius v Powered Hybrid Convertible

The 3D Printer has arrived! Time to make some 3D printed parts!

 

Waiting for a replacement cable to arrive. One of the cables was damaged (by me) during assembly. I'll provide an update as soon as it is running.

 

First part started on the 3D Printer!

 

The completed part. It is the prototype for the steering column adapter bracket to fit the Prius V steering column into the Firebird dash mount. If I like the way it fits, then I'll use this as the foundry pattern to have the part made from cast metal.

 

Material TBD. Let's get there first!

 

Second 3D printed part is a snap-fit adapter (white part) for the Firebird center A/C Duct (black part) to connect to the air hose going to the Prius V A/C unit. It snapped right on.

 

I have the unfair advantage of having access to the Solidworks 3D CAD software, since I teach it at Del Tech. I was also a design and development engineer for over 40 years. Designing these parts is like zen therapy for me. I take whatever measurements I need on the car, then design the part, then dump it into the translation program for the 3D printer. I can usually turn out a new part that way about every 2 to 3 days.

 

I'm using every inch of the 3D printer bed.

 

The latest three 3D printed parts snapped right together on the first try. (Adapter frame, right duct, left duct.) Onward!

 

Three steps in the 3D printing process.
1. 3D CAD model creation.
2. 3D Slicing program model.
3. Final 3D printed part.
(This is FUN! I'm having a blast doing this!)
This part is the right a/c duct extension behind the glove box area.

 

First five parts fitted together.

 

The adapter is mounted on top of the a/c unit. Now on to the connecting ductwork.

 

Before and after photos of the latest 3D Printed duct added to the Firebrid a/c system. The previous design was going to run into the wiper motor, thus the change. Step-by-step I'm getting closer to my goal...