Cable Repair Mold

thingiverse

This is a straightforward mold for fixing snapped multi-strand wires using Sugru or an equivalent molding material. First, determine the dimensions of your wire and the diameter of the repaired strands, then customize and cast accordingly. This mold was designed specifically to repair a broken bike computer wire. For casting instructions, please refer to the following steps: After Printing Materials Needed: Sugru 2 bolts Clamp Soapy water Paint brush Masking tape (optional) Casting Instructions: Print with an infill of 25-35% - the mold will be compressed and a lower infill may cause damage. Clean any rough edges or surfaces to create a smooth mold. The two halves should fit together cleanly. You can also sand both halves for a cleaner interface. While you work on the next steps, warm up a packet of sugru. Place at least two bolts in the mold to help with alignment. A bit of masking tape over the bolt heads will keep them from falling out while you work. Paint the inside of the mold with soapy water, covering every surface that sugru will come into contact with. The water will act as a release agent. If you don't use water, you may not get a clean casting. With clean or gloved hands, open the sugru and form a rough sausage of approximately the same size as the intended casting. Use more sugru than necessary to be safe. Push the sausage into the half of the mold with the bolts. Align the other half and press it firmly down. Quickly use a clamp to press the two halves together. Make sure not to leave the sugru in the mold, as it will force out the water and get stuck. Pull the halves apart and gently remove the casting from the mold. Try not to touch it more than necessary. Hang the casting in a safe spot for at least 24 hours. Thicker castings may take longer to cure. Finally, clean off any unwanted flash.