Aldi Mower Fuel Cap

thingiverse

Using my brand new Aldi mower for the second time, I discovered that while mowing, the fuel cap had come loose and was dangling from the cord. Upon inspection, one side had snapped off (the one with one of the 2 lugs), making it impossible to secure properly anymore. To solve this problem, I created a replacement mower cap. This custom cap fits Aldi mowers that use two lugs to keep the cap in place after it's been pushed on and turned by 30 degrees. After researching fuel-safe filaments online, I decided to use Taulman 645 nylon for this project. Common materials like ABS and PLA are prone to deterioration from fuel, so I opted for a more reliable option. Although I haven't tested other materials extensively, the nylon has performed exceptionally well and remains unaffected by fuel. If you're an expert in printing with nylon, feel free to use your standard settings and proceed with caution. However, if you've had limited success with nylon in the past or are unsure of how to achieve optimal results due to infrequent use, I recommend the following tips for my Prusa printer: Firstly, ensure that the Nylon is completely dry before printing. To do this, place it in a dehumidifier overnight and keep it running while you print, pulling the filament out as needed. Moist nylon will hiss, spit, and steam during printing, resulting in subpar results. To achieve the best possible outcome, print slowly and thinly. Nylon is elastic, so printing too quickly can cause warping and delamination (at least for me). I print nylon at 25 mm/sec with a 0.1 mm layer height. Printing hot also yields excellent results. I found that starting with a first layer at 250 degrees and then printing the rest at 270 on a 100 degree print bed works well for me. To enhance adhesion, use a single layer of glue stick. A thin layer is sufficient; applying too much can be counterproductive for me. Finally, I recommend printing a 20mm brim to help with bed adhesion and reduce warping. As the material cools, it tends to shrink slightly, which can cause warping and lifting. By adding a single layer brim, the corners are unable to lift and warp up.