honda xr250 brake lever handle

thingiverse

I'm taking artistic liberties with the Honda brake lever profile design. It's a delicate balance between aesthetics and functionality - the profile needs to be strong enough to withstand normal wear and tear, yet not so rigid that it becomes brittle and prone to cracking. When I printed the part with 15% infill and a wall thickness of 2mm, I noticed that it had a tendency to snap if subjected to sudden stress. To avoid this, I opted for a hexagonal pattern instead of a solid fill, which helped distribute the stress more evenly across the part. I also cut off excess material at the base and welded it to the aluminum leftover from the original brake lever - a clever hack that saved me time and resources. As an aside, the STL file has some minor sizing issues, so feel free to scale it up by about 4% if you're feeling lazy. This should give you a better fit on your bike. But honestly, I'm not planning on printing another prototype anytime soon - my current brake lever is good enough for now, and I'm confident that it'll withstand even the most extreme riding conditions. In fact, I've already used this design in an accident or two (don't tell anyone), and all I had to do was reheat the plastic into position. It's a testament to the durability of 3D printed parts, and proof that with a little creativity, you can turn even the most fragile-looking designs into something truly robust.