Honda Brake or Clutch Pedal Stopper Pad (Civic Accord CRX Prelude)

thingiverse

If your Honda vehicle brake lights won't turn off, and you notice some weird broken plastic pieces on your floorboard near your pedals, then this fix is probably exactly what you need. I hope it helps someone out. This part should fit a wide range of model years for Honda vehicles and serves as a direct replacement for the OEM part number 46505-SA5-000, as well as the Dorman 74015 (only the white replacement part included in that kit). The original design comes from http://www.thingiverse.com/thing:924433. I really appreciate MS3FGX for giving me a starting point on my own attempt. Instead of using OpenSCAD, I used Autodesk 123D since I'm familiar with it (still relatively new to 3D printing and haven't gotten my feet wet with OpenSCAD yet). Unfortunately, I had a rough time inserting MS3FGX's part after printing and had to use a file around the widest part of the 'cone' diameter several times before I could forcefully insert it into the hole in the pedal arm (maybe just the result of my 3D printer's tolerances). I also took the small edge of a flat jeweler's file and filed a small indentation around the base of the shaft, similar to the original part, which should help keep it from falling out over time. This version has the indentation included. My hope is that this part is virtually an exact duplicate of the original OEM part that was in my 1994 Honda. I'll just admit right now that I never printed it since I had already modified MS3FGX's part to fit my car. I'm posting this version as an afterthought to help out anyone else who wants one a little closer to the original OEM part that came with their vehicle. I used the 3 broken pieces on my floorboard to take these measurements from (see my measurements in the included image). The center shaft was not broken, so I was able to get good measurements from it using calipers. The 'head' was in two pieces, but I was also able to get good measurements from those pieces as well. Anyone printing this may want to consider the tolerances inherent with their 3D printer to ensure the part doesn't get much bigger. It may make it difficult to insert into the pedal arm and may require some slight sanding/filing to correct. As MS3FGX mentioned in his original comments, you'll want to ensure the infill is sufficient to lend the part enough strength to hold up under pedal punishment (at least 30%?). What I did was use my slicer (Cura) to increase the 'bottom layer thickness' until there was no infill whatsoever in the head of the part, which gets sandwiched between the switch and the brake pedal arm.