hi gentlemen driver,

rdk sensors on my CUP 1 wheels were gone, so I ordered 8 , my dealer told me it was a 2-3 days wait. no problem.
I broke 3 during installation, as plastic went brittle and aged badly despite they came in a box.

dealer told me to come there with my car , maybe I am not able to put them on: he broke another 4 .
he refunded me money , I went home and started to put together one with loctite.

final result:




so I glued the cover and put in a shaped box, pured siliconic gum in it and let it dry for 24 hours.










after the gum is completely dry, I dismantled the box, removed the molding and the debris of original sensor cover, I knew I had to sacrifice it because it was so brittle








finally I can pour in the molding the aroflow 514, poliurethanic plastic I use also for my job, mixed with 45-47% (weight ratio) of his hardener.




2 minutes and the first plastic plastic was ready.







As I thought first attempt is not perfect (some bubbles and surface not as smooth) , but I went to 44% of hardener and things went better.

tried again and with 35 grams of aroflow and 14 grams of hardener(40%) I found the best compromise. they are a bit hard to put on the sensor, but I think it is better just in case the plastic get soft with the heat.



made 8 for my car,I sprayed some primer on , waiting for the mattblack paint coat while you're reading.


I hope you like it.

Francesco from Italy

 

Nice work, thanks for sharing

 

thank you. Now I think I will make some more set , for those interested....

 

This thread is full of WIN for those wanting to replicate plastic parts.

Can you please post/provide specific components/names/sources for the pured siliconic gum and the aroflow 514, poliurethanic plastic?

 

ok, I will post some specs of components asap!

 

I'll take a set!

 

here's some info about AF514 directly from the factory I buy the stuff

http://www.pozziarosio.com/en/compact-2/

http://www.pozziarosio.com/securecon...w_digitale.pdf

http://www.pozziarosio.com/securecon...s_digitale.pdf



before I will start to poduce some more, I prefer to test this stuff on the car.

after that I will make some sets , Painted or raw PU .

Francesco

 

I think this is really great that we have an alternative. However -----

I sell a lot of these and never had any feedback about them breaking.

If the plastic was brittle that may be an age issue and all my stock is fairly new manufacture and very flexible with no cracking/breaking.

They are extremely flexible and I cannot break them at all. I used all my force to try and break the part but it just flexed and returned to the original shape. See picture.

I suspect you have new old stock for them to be brittle like that. Check the manufacturing date on the package.

Part was not available some time ago and Porsche restocked and they have about 800 of them. And not exactly an expensive 0part at $3.88 list price each.

The latest stock were manufactured in September 2013.

 

Well, in that case, I don't think I need four....

 

Labels on the boxes say 2013.
maybe they wanted to clear out old supply before starting to sell the new one. I thought.

as I see in the picture,the thick part can flax, so those I bought, the thin edges were really hard and brittle.Anyway, installing 2-3 of these the central part cracked.one , yet broken , fellfrom the table and disintegrated in a million pieces.

something however went wrong with my 8 schutzkappe.

today I will install the repro parts I have , I will test them and I will search for faults and problems ....
if they are good enough I reproduced something good at no cost.if they have problems with weather , car wash, heat from tyres/brakes/etc . I will get original parts ....

interestingly, my dealer asked me 4, 55 euro each.I think I can ask him some question .....

 

Thanks for sharing the information on the plastic moulding components.

 

Just installed a set of these on the D90s on the Cobalt GT. I could swear the covers I got from Mark are somewhat different from the 'old' ones I used on the last sets of D90s I refinished in 2011 and 2012. They're taller, definitely more pliable like the ones Roger shows squished.

Anyway, I couldn't press them on with my hands, unlike the old ones. Trick is a 27 mm socket and a 3 lb hammer, gentle taps.



Old sensor covers: