Husky Toolbox Drawer Locking Mechanism

thingiverse

So you've got this great Husky toolbox that cost $800-1000 and now the drawers won't stay in place anymore, rolling out randomly at random times. What's going on? Well, it comes down to two things. First, either the body or legs of the mechanism are broken, or the retainer is damaged. Second, the drawer itself has a metal "hook" that used to grab onto the retainer and now it won't pull with the drawer's actuation anymore. This causes the retainer position to not reset properly and the drawer to stay open. This design isn't just meant to replace what you've got, but also improve on it. Here are some of the key upgrades: * The legs are thicker with more support structure and a less angled design. * The "tongue" is larger and sturdier, sticking out a bit farther than before. * Some of the walls that meet the spring are thicker too. I noticed while working with the stock pieces that they had a tendency to crack or break when removed. But with my redesign, only one leg broke after 5-6 removals in a row, and the body and everything else stayed intact. **YOU WILL NEED TO ENABLE SUPPORTS TO PRINT THIS** You can use all the normal settings for this particular piece, but here's what I used: * 100% infill with Gyroid * .1 layer height * Support enabled with Zig Zag at .05 support to print Z distance * Initial build layer at .2, printing at 15mm/s speed * Using the latest version of Cura To install this new mechanism: * Remove the old one - it's going to get destroyed, which is fine. You'll need the springs. * Assemble the new pieces with the spring and some lube on the spring and retainer so it slides onto the drawer's hook easier. * Line up the part with alignment squares and put either both bottom legs or top legs in, getting that side's bottom alignment square nearly all the way in. * Once that's in, use a screwdriver to apply pressure near the alignment squares on the leg to push it into place. Just be careful. * The top two legs should now either slide into place or be very close. Make sure they don't go under the rail - instead, put them behind it and press against the lip of the rail and leg. Get your alignment squares snugly pressed in (this keeps it from hitting the drawer) and then slightly bow the legs out into the mentioned orientation with a screwdriver. Test it out a few times to get it perfect. I've already fixed 3 drawers with this design, and they're working flawlessly. This is my first time designing something in a 3D modeling software, so sorry if there are any small issues - although there should be none. *Update 4/15/2019: Made the main unit closer to OEM looking, fixed some geometry issues on the original model that was causing undue weakness on certain areas.