ngng

A totally non-critical part that opens the door failed on my car /s. I figured I’d pay the Porsche tax and it would be an easy fix, turns out, I was wrong

“Thank you for contacting us. Unfortunately that part number you have supplied is no longer available through Porsche. Looks like they have discontinued it. See below.”

Probably spent a few hours iterating over the various designs and hours, and hours learning how to generate toolpaths in Fusion and operating the mini mill. For sure a learning experience, but pretty cool to go from design to physical part.

This casting retained a pin that held the pull strap in place. Well, it was supposed to.


This is what it should look like (passenger side).


So I modeled a part, and then realized I 100% didn’t want to machine it.


So I tried to simplify the design. The new part slips on and will be epoxied over the existing door handle where the existing adapter screwed to.


3d printed the first few prototypes




Then proceeded to crash a few end mills

ilko

Great job! Is it the same part for both the driver and passenger side? And are you able to produce more by chance? I'd be interested in a set if so. Since this part failed on you it will likely fail on others...

ngng

not sure I want to sell them just yet, it's pretty crude haha. I'm OK with it, mainly because I can't open my door without it. this part would fit on either side.

Mr. Adair

That's next level! I would have call some breakers and tried to find a used piece! Impressive as hell...

ngng

Whelp, the passenger door pull broke. Looks like I need to make another one.

Spyerx

porsche doesn't sell the full actuator? I recall a long time ago when i changed to pulls on my 997.1 i had to replace the full internal part...

RAudi Driver

I see a market here for someone.....ngng.

ngng

Not that I'm aware of the the RS pull.

ngng

I gota plenty of stuff I need to make for myself hah

Steve Theodore

You have real skills my friend. Color me impressed!

ngng

Looks good from afar, but it's far from good. If you look closer at the model vs the actual part But, now that I need to make the part, I'm going to try it against now that my skills have improved.

Belinko

you might want to deburr and/or file those corners/edges. Sanding or tumbling would go a long way to make them a little nicer too.

ngng

I hit it with a whip. Had I known what I know now I would have done a 3 thou chamfer pass on all the edges. I also would have calculated my feeds and speeds vs dragging a slider to max 😂