Headlight Adjusting Knob

thingiverse

After swapping out my headlights on my trusty 2003 Expedition, I discovered that getting them aligned was quite a challenge due to the adjusting screw's small size and awkward location, which made tool access extremely difficult. To overcome this hurdle, I came up with a brilliant solution - crafting two custom knobs to fit snugly onto the shaft of the adjusting screw. The hex portion of the screw is tantalizingly close to 4mm in diameter, so I designed the knob with a precise 4mm hex center, ensuring a perfect fit that should stay put. I printed these ingenious knobs on my Ultimaker PLA, but ABS would also work beautifully (you might need to make a slight adjustment if the fit becomes too snug due to the added shrinkage). Print Settings Printer Brand: Ultimaker Printer: Ultimaker 2 Rafts: No Supports: No Resolution: .2mm Layer Height Infill: 20% Notes: A 0.4mm nozzle, 1.2mm shell and top/bottom thickness were used, with no rafts, brim or supports. How I Designed This I employed TinkerCAD to bring this project to life, starting with a community shape generator - Cog Ring 2 by Yoda Wars for its knurled texture, which I scaled up to 24x24mm. A solid cylinder was then added to fill the center, followed by a 4mm hex hole in the middle. Grouping all these elements together proved to be a straightforward process.