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Old 1st April 2018, 08:04   #11
grout20
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How do you get at the cog? Is it easy to take the unit apart?
I can open the "inspection hatch" on the side of the unit but can't see any broken cog teeth.
Happy Easter, all
John
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My 2.5 V6 Connoisseur SE Auto 75 is the
• 20,516th 75 to be made out of 112,381
• 787th 2.5 V6 Connoisseur SE to be made out of 3,671
• 1,248th Wedgwood Blue Metallic (code: JBH) to be made out of 7,515 code JBH 75's
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Old 2nd April 2018, 14:33   #12
egremont
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Default A lot of effort went into this, but costs would be too high.

We contacted the commercial division of one of Melbourne's leading universities.
The idea was to re-manufacture the cogs in metal using 3D printing. When I was at their premises, they were manufacturing a part - incorporating three different alloys - for an aviation company. The staff told us that all their 3D printers are from Germany and that the aircraft part would take 24 hours to complete.
At the local International Air Show (it is a biennial show) they displayed a working jet engine that had been totally made on their 3D machines.
One of my fellow club members later discussed the proposed manufacture of our cogs.

We didn't want plastic as there is quite a sudden impact when the gears reach the stop "buffer" - I liken it to a rail vehicle hitting the buffers at the end of a line.
My son-in-law prepared a set of cogs in plastic - only for checking against our drawings.

We intended to have the cogs made in a strong metal that would withstand jarring - the company uses titanium in a lot of their work. However, considering the time to clean-up the prototypes - supports have to be included in the programme to hold parts during manufacture and later, these "supports" have to be cut out and the items cleaned up.

We would have had to place a minimum production run to reduce costs and even then it was considered that members would prefer to continue with the second hand plastic BMWs units - whilst these remainl available.
I did consider placing a photo of the two main cogs - formed in a blue plastic.

Saddened by the fact that we couldn't get this project off the ground - after so much effort.
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Old 2nd April 2018, 14:58   #13
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Quote:
Originally Posted by egremont View Post
We contacted the commercial division of one of Melbourne's leading universities.
The idea was to re-manufacture the cogs in metal using 3D printing. When I was at their premises, they were manufacturing a part - incorporating three different alloys - for an aviation company. The staff told us that all their 3D printers are from Germany and that the aircraft part would take 24 hours to complete.
At the local International Air Show (it is a biennial show) they displayed a working jet engine that had been totally made on their 3D machines.
One of my fellow club members later discussed the proposed manufacture of our cogs.

We didn't want plastic as there is quite a sudden impact when the gears reach the stop "buffer" - I liken it to a rail vehicle hitting the buffers at the end of a line.
My son-in-law prepared a set of cogs in plastic - only for checking against our drawings.

We intended to have the cogs made in a strong metal that would withstand jarring - the company uses titanium in a lot of their work. However, considering the time to clean-up the prototypes - supports have to be included in the programme to hold parts during manufacture and later, these "supports" have to be cut out and the items cleaned up.

We would have had to place a minimum production run to reduce costs and even then it was considered that members would prefer to continue with the second hand plastic BMWs units - whilst these remainl available.
I did consider placing a photo of the two main cogs - formed in a blue plastic.

Saddened by the fact that we couldn't get this project off the ground - after so much effort.
Well, I would say that puts the ball back in Ameph's court. It is a shame, but thank you very much for trying. I know it was quite an involved process.

Quote:
Originally Posted by Ameph View Post
Hi, did you ever resolve this? I have been running a 3d printed cog in my 75 now for about 6000km with no problems. Not sure how long it will last but they only take me 3 hrs to print so I can replace them as needed.
Ameph, will you please keep us updated about the longevity of your printed one? Also, would you be interested in printing them for members if they need them?

Cheers,
Glenn
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Old 3rd April 2018, 07:46   #14
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I am happy to print them out. I believe John Chambers from the SA Rover club is going to bring some over to the Australian convention this month for those in Oz that might be interested.

I considered printing them in metal but was concerned they would then damage the smaller cog instead. That is a much harder one to replicate so I stuck with plastic. I can print the plastic at home as well so it makes them a lot cheaper to manufacture.

Without making this an advert they don't cost much ($16 AUD ea) but the postage is $8.50 anywhere in Australia for up to 500gms so as they don't weigh very much at all it is better to combine orders through clubs.

I am also happy to send o/s but don't know the postage costs.

Anyone who wants one can send me a message. Cheers

Last edited by Ameph; 3rd April 2018 at 07:49..
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Old 3rd April 2018, 07:54   #15
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Quote:
Originally Posted by grout20 View Post
How do you get at the cog? Is it easy to take the unit apart?
I can open the "inspection hatch" on the side of the unit but can't see any broken cog teeth.
Happy Easter, all
John
Hi John, we had to carefully disassemble the whole unit to get to the cog. I am going to see if I can find a faulty unit from a local wrecker and do a tutorial on how to fit the printed ones but it won't be for a month or so due to other commitments.
Andrew
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Old 3rd April 2018, 16:00   #16
reclamation ray
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I have developed a problem with the abs and brake warning lamps staying on when engine is running, when I first switch ignition on I used to hear like a self test whirring I think coming from the traction control unit. Is it possible that this unit has failed as thread describes or am I clutching at straws ? Any help or advice would be very much appreciated.
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Old 3rd April 2018, 16:20   #17
grout20
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Quote:
Originally Posted by Ameph View Post
Hi John, we had to carefully disassemble the whole unit to get to the cog. I am going to see if I can find a faulty unit from a local wrecker and do a tutorial on how to fit the printed ones but it won't be for a month or so due to other commitments.
Andrew

Hi Andrew
Thanks.... that would be good.
I might try to remove my unit, open the inspection flap and shake it to see if any teeth fall out! I've read somewhere that if that happens the unit may still work.
Will have to see!
Cheers f'now
John
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My 2.5 V6 Connoisseur SE Auto 75 is the
• 20,516th 75 to be made out of 112,381
• 787th 2.5 V6 Connoisseur SE to be made out of 3,671
• 1,248th Wedgwood Blue Metallic (code: JBH) to be made out of 7,515 code JBH 75's
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Old 3rd April 2018, 16:26   #18
grout20
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Quote:
Originally Posted by reclamation ray View Post
I have developed a problem with the abs and brake warning lamps staying on when engine is running, when I first switch ignition on I used to hear like a self test whirring I think coming from the traction control unit. Is it possible that this unit has failed as thread describes or am I clutching at straws ? Any help or advice would be very much appreciated.
Hi Ray
Sorry, I can't help as the car is new to me, my previous one didn't have TC and my TC warning light (only) is always on.
So I don't know if I should be hearing a self test whirring sound!
Hopefully someone more experienced will come on thread and advise.
Good luck!
John
__________________
.

My 2.5 V6 Connoisseur SE Auto 75 is the
• 20,516th 75 to be made out of 112,381
• 787th 2.5 V6 Connoisseur SE to be made out of 3,671
• 1,248th Wedgwood Blue Metallic (code: JBH) to be made out of 7,515 code JBH 75's
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Old 13th January 2019, 21:48   #19
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Hi Ameph, I'm very keen to buy 2 of these cogs that you have re-manufactured - with hard to get parts I always like to have one as a spare. How do I go about ordering and paying for 2 cogs? I am in Boronia Vic 3155. Cheers, Bill

Last edited by busybeeau; 14th January 2019 at 22:10..
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Old 13th January 2019, 23:00   #20
Terryf
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Quote:
Originally Posted by kaiser View Post
I don't know of one car with that installed! (not that that might mean much)
Most have a lonely looking connector under the battery, which I believe was supposed to connect to this.

I am very surprised why the Australian cars would have this fitted!
Mine has but not used it much.

Last edited by Terryf; 13th January 2019 at 23:01.. Reason: missing word
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