KIA eNiro Niro EV MY20 MY21 Frunk

thingiverse

<h1>List of parts</h1> Parts printed: - 1x support small, height: 35mm - 1x support small, height: 45mm - 1x support large, height: 45mm - 1x support large, height: 65mm. Other Parts - 4x original rubber damper (2x OD 30mm and 2x OD 22mm) taken out of the original plastic motor cover - eurobox 20l (60x40x12cm): https://nl.bauhaus/kunststof-boxen/bauhaus-eurokrat/p/21863435 - lid for eurobox (60x40cm): https://nl.bauhaus/kunststof-boxen/bauhaus-deksel-voor-eurokrat/p/23099157 - 8x carriage bolt M8x30 with M8 nut: https://nl.bauhaus/draadeind-schroeven/profi-depot-slotbout-met-moer/p/10815453 - 8x washer for M8: https://nl.bauhaus/carrosserieringen-veerringen/profi-depot-vlakke-sluitring/p/10826497 <h1>Design changes</h1> In this remix of the original supports we changed the following to the design using the free Onshape CAD tool - Added a radius to all sharp corners/edges to prevent stress concentrations - Added a big radius to the inside corners where the flange connects to the cylinder on the two big supports - Adjusted the inner diameter of the cylinders to fit the original rubber dampers from the KIA motor cover/cap instead of printing rubber dampers and fitting those (see pictures) - Reduced the height of all 4 cyclinders by 5mm to compensate for the original dampers which protrude 5mm when the largers damper diameter is flush with the top of the cylinder (see pictures) - Increased the inner diameter of the through holes to 8.5mm for a easier fit of the bolts - The through holes have a chamfer at the bottom, so that the square start of the bolts fit well. - Added small radii at all outer corners for better printabillity - Update 20210914: Replaced 1 small support with a 45mm version to make the box more level in the car - Update 20210914: Increased distance between the through holes of the small supports to 60mm to eliminate interference of the wrench with the support during assembly - Update 20210915: Added drill dimensions <h1>Printing</h1> For Slicing Ultimaker Cura was used. The whole set was printed in one run. - Total build size ~126x190x65mm (~3mm spacing between parts) - PLA matt black from reel. Approx. 250g needed in total (71.2m of 1.75mm wire). - No support needed, no overhang. - Layer height 0.2mm - 35% infill cubic (higher infill has little effect) - Wall lines: 3 (1.2mm) - Infill overlap: 45% (overlap between infill and the walls, for better adhesion of the infill) - Speed: 55 mm/s (infill 110, walls 27.5, first layer 27.5mm/s) - Brim, only on outside: 5 lines, for better adhesion to the printbed The set was printed on a Anet ET5 Pro in just under 20h. Only the brim needed to be removed before assembly. <h1>Assembly</h1> - 8 carriage bolts M8x30 to minimize the protrusions inside the box - Normal nuts instead of self-locking (and washers) to prevent excessive stress of the carriage bolts on the box floor in the box holes. To prevent loosening of the nuts, use Loctite or similar. - Same Bauhaus eurobox and lid as the original.