2006 Hyundai Elantra Key Fob Case Replacement

thingiverse

Human: 2006 Hyundai Elantra Key Fob Case Replacement=======================================Why--------The key fob case on both key fobs I bought when I purchased the car started cracking and falling apart in exactly the same way (see the photos).Given that the car is almost 15 years old, I wasn't surprised, but when I called about replacing the fobs, I was told it would cost around A$450 each.Not wanting to spend close to A$1000 on replacements, I bought a cheap 3D printer with the intention of designing and printing my own key fob case.Yes - this problem is what motivated me to buy a 3D printer. How much did it save me? By my calculation (ignoring the time spent designing), about $700 in the clear. Take that, key fob industry!What--------There are three parts to the print: The front and back of the case in PLAThe button in flexible PLAYou will also need Four 8mm M3 screws and nuts - the ones I used have a hex key bit rather than screwdriver bits, so the heads are quite tall. If you're using screws with traditional Phillips heads, you might get away with 6mm.A scrap of kitchen foil for the bottom battery contactA tiny amount of superglue to make the "window" for the LED indicator light and improve water resistance.How-------First print the parts and then quickly test them by pushing everything together and making sure it all fits. The friction fit between the two halves of the case should be quite tight, holding itself together nicely.Next, before doing the final assembly, put the screws and nuts in and screw it all together as if it were the final assembly. The case is designed for the screw heads and nuts to sink into the case, but the fit is quite tight - just screw it all together first to get everything in place.The nuts on the bottom should wedge in place, and then you can remove the screws.Grab the kitchen foil scrap and press it into the bottom half of the case where the battery compartment is with your thumb, and lift it out again. Use the impression made in the foil to cut it out to the right size, and then place it in the bottom half of the case.Make a second thin piece to go from the base and up the "ramp" to the top contact point to ensure a good connection with the circuit board.Put the battery in place (positive terminal is downward, as indicated in the case itself).Grab the circuit board, and place it with the chips etc upward on top of the case, oriented with the LED indicator end away from where the strap attachment is.Get the lid, and mix up a small amount of superglue - this isn't to stick the key fob together!Using a toothpick or similar, dip it in the superglue and fill the tiny hole in the lid with a small amount of glue. This will create a water-tight transparent window for the LED to shine through so you can see it flash when the buttons are pressed.Wait for the superglue to set.Next, fit the button to the lid, and then fit the halves together.Holding it together with your fingers, do a quick button press test to make sure that it works. I haven't had much trouble with this, but if it doesn't work... - make sure that nothing has shifted inside - that the battery is in the right way - the kitchen foil connection is alright - check everything is in its place and the right way aroundOnce you're satisfied that it's all good, do up the screws nice and tight, test again, and you're done!