Giant switch control dropper post keys

thingiverse

These are keys for Mountain Bike dropper posts. Specifically, the Switch Control Dropper by Giant, but they might also work on other dropper posts. This precision part allows the seat post to travel up and down but prevents it from rotating. The original keys are made from nylon and are intended to shear off to prevent further damage to the seat post when forced to rotate. However, these keys are very hard to find and I didn't want to spend a couple hundred dollars to replace the seat post after a hard crash. This part took less than 30 minutes to print, trim to fit, and install. Because these are precision parts, I intentionally made them very slightly too big, then used fine sandpaper on a flat surface to carefully bring them down to size. I made three different thicknesses so that I could choose which size had the best fit. I have been on several rides since replacing the keys and they are working great. 1. Print the keys using PLA, PETG, Nylon, or ABS. (I used PETG) 2. Remove the seat post from the bike. Take care to feed the cable into the frame as you pull the seatpost out and then detach the cable from the seatpost. 3. Unscrew the top seal and the bottom cap of the tube. There is no need to remove the seat. 4. When you pull the tube apart, there will be grease and shavings of the old keys. All the contaminated grease will need to be removed using a rag. 5. Remove what is left of the old keys and make sure the keyways are clean. 6. Test fit the new keys. They need to fit snugly in the keyways, so some trimming will be required. I used fine sandpaper on a flat surface to gently trim the sides of the keys until they could be gently pressed into the keyways. If needed, use the sandpaper to polish the top and bottom of the keys to reduce friction. This file has three different thicknesses of keys. Test each one to see which thickness you will need. Too thin and the keys will shear off again. Too thick and the posts won't raise and lower. The middle size worked best for me. 7. Insert the new keys into the Keyways and apply a thin coating of shock grease to all the inside serfaces. I didn't have shock grease, so I used automotive grease and it worked just fine. 8. Screw the bottom cap back onto the inner shaft first. Then insert the inner shaft inside the tube and finish screwing on the bottom cap to the tube. 9. Now tighten the upper seal to the tube, and wipe off any excess grease that might be on the ouside of the dropper post. 10. Reattach the cable and insert the dropper post back into the frame. genly pull the cable as it comes out of the frame near the handlbars as you insert the seatpost. 11. Align the seat to the frame and tighten the seatpost bolts. 12. Finally, test the dropper post to to ensure it is working properly. You may need to raise and lower it several times untill the grease is evenly spread and trapped air is allowed to escape. 13. Enjoy your ride.