Toggle switch lever covers

[lesthegrngo]

Hi all

As I have a lot of time on my hands to look at bettering bits of the rig, one topic that kept cropping up when designing the panels was that the toggle switches I am using are not right.  The types I'm using are the little single and double pole ones with the blue plastic bases, the larger single pole ones with the bakelite coloured base and the even larger single pole ones with the bakelite coloured bases. All the ones I'm describing are the easily found cheap ones on fleabay.

The problem is that while the larger ones have nice solid levers, often space requirements mean they don't fit, meaning that I end up having to use the little blue ones. A collateral benefit with those is that I have machined my PCB's so they direct mount, making a much tidier installation. 

The downside is that the actuating levers themselves are somewhat anaemic, looking disproportionaltely small and skinny for the panels they sit in. So I have been wondering how they could be improved, and knowing that there is no way I can replace them due to the construction of the switch, I thought about covers.

I have a resin 3D printer, and browsing through the different sites in search of knowledge I came across some flexible resins, and started wondering if it was possible to 3D print a flexible resin sleeve shaped internally to fit snugly on the switch lever, but with the external shape of the correct panel switch toggles.

It's going to be Christmas before I get my shipment and therefore all my stuff so I can't test this out yet, but wonder if anyone has researched this method before, and if so whether there was any succes with it. I can get some resin to test eventually, but right now I am not sure how much elasticity is in the material. There are pourable two component silicone rubbers out there so maybe they could be moulded using  3D printed moulds, but suspect that silicone rubber would not have the strength.

Another thought was using the silicone rubber as a bonding agent to stick covers over the toggles.

Anyway, as usual any feedback and thoughts are very welcome

Cheers

Les

Edited November 6, 2021 by lesthegrngo
spelling

[agrasyuk]

Molding materials come in different elasticity. If you need the harder one  you probably going to better off with urethane based molding material. Silicone parts are also VERY finicky as far as gluing. 

Picrured: the blue mold is silicone , the brown one is urethane

 

 

That said,  my vote is to always use full size proper toggle switches. 

Good luck!

[lesthegrngo]

Thanks - as it happens I used polyurethane before for moulding when making bits for scale modelling, and I must have the majority of the stuff left somewhere. And as for silicone, the only thing it really bonds to is more silicone (ask me how I know...), however maybe an insert 'sock' in a harder resin part to make one fit the other snugly..? I suppose a bit of experimentation is in order.

One of my design limitations is that everything I make has to be flat packable Ikea style, for cases like right now when I move countries. As a result while I would like to be able to be less compromised with the stuff like the toggle switches I have to accept it. In a lot of cases, truth be told, many of the switches are used rarely, if at all, during most of the sim use so it is not such a bad one. Where possible I do use the nice big ones where they are used regularly during gameplay as without a doubt the tactile quality is just as much a part as the visuals. But I do have to be realistic and realise that I have to prioritise where to put my effort.

Another part is the ability to design something that makes a lesser solution work when all you can get is certain parts, which I imagine is something a lot of people on these forums appreciate - I immediately think of the rudder pedals made from bicycle handlebars!

 

Cheers

Les

[No1sonuk]

I wonder if PETG (or whatever resin you use) would be flexible enough if you make a tiny split in the side(s), then glue it after fitting.
I don't know about the resin process, but could you force the lever into a "hard" print before it's cured?

Or print them in two halves and glue together on the switch lever.

Edited November 6, 2021 by No1sonuk

[PhoenixRising]

I found some toggle switches at Ali that are 12mm, instead of 6mm, but are small on the bottom. I haven't tried them because I haven't had a new project recently. They are also more expensive. https://m.aliexpress.com/item/33004812439.html?spm=a2g0n.shopcart-amp.item.33004812439&



Sent from my moto g stylus 5G using Tapatalk

[Vinc_Vega]

I use those switches from RS-Online by "TE Connectivity" and "RS Pro".

Here are some measurements: https://docs.rs-online.com/2161/0900766b81587616.pdf

 

Regards, Vinc

Edited November 7, 2021 by Vinc_Vega

[lesthegrngo]

They look good Vinc.... but the overall cost is going to be significant once you cover all the switches. For some essential ones, yes, definitely, but for non-esential ones? I have little to lose by trying.

I've ordered some of this stuff "PrimaCreator Value Flex UV Resin" as I need to make some handles and flexible parts for my driving rig too and some cable management parts. Not too certain it will be flexible enough for this idea, but if it works it may provide a cheap solution for those lesser used ones 

Quote

I wonder if PETG (or whatever resin you use) would be flexible enough if you make a tiny split in the side(s), then glue it after fitting.
I don't know about the resin process, but could you force the lever into a "hard" print before it's cured?

Or print them in two halves and glue together on the switch lever.

That's a good point about the curing, again it is worth seeing if that is an avenue, as I know that some resins actually shrink once they cure fully. Not much, but maybe enough?

 

Cheers

Les

Edited November 8, 2021 by lesthegrngo