Hori Hayabusa Oversized Actuator

thingiverse

Oversized actuator for Hori Hayabusa lever. I have a Kowal 1mm actuator in my Sanwa JLF, but I have heard it is not compatible with the Hayabusa stock square gate without sanding it, as the edge catches on the lip. Assuming a stock JLF actuator is ~10.8mm at the throw, this actuator is 1.5mm larger (12.3mm) at that end, as I have read the Hayabusa has an additional 0.5mm throw over the JLF. I initially modeled this design on the Kowal actuator, where the engage end that hits the switches was approximately the same diameter as stock, 16mm, with straight cylindrical outer walls. In order to smooth out the part that is said to snag on the gate, I began with a subtle beveled edge. I could see, though, in a test printing that the bevel still had the potential to catch. In going through a number of revisions, I have opted to enhance the bevel in order to eliminate any sharpness and give the outer walls a slight conical shape that expands from 16mm to 16.3mm. The inner cup that holds the spring is also conical like the stock actuator to allow for the spring to move more naturally. This actuator works as it was designed to. The one caveat I found is the diameter of the shaft hole is a bit too tight. It was a simple fix to get it to the right size by rolling sandpaper into a tight tube, sticking it through the actuator and sliding it along the sandpaper tube back and forth until it was able to slide onto the lever shaft. This could be fixed in the model, but I found it preferable to make it tight and sanding it out a bit, rather than printing it too large and risk it being loose.