Repair Parts for Discovery 2 Dash

thingiverse

These parts are meant to repair/replace the commonly broken features on the back of the instrument cluster surround on a Discovery 2. Parts have been tested on a 2004 and I assume would fit any Discovery 2.There are two separate STL files. One for replacing the clips near the top back of the part and one for repairing the two screw holes near the bottom of the part. The clip replacement is for the left clip. If you need the right side, just mirror it in your slicer.The part for replacing the screw holes includes both screw holes in one part. You could easily chop off a small section if you only needed to replace one hole but I needed both plus my dash was starting to crack in that area so the extra material from the printed part should hopefully keep that from getting worse.Procedure:Print whatever parts you need. I'm more of a designer than a printer so I won't make suggestions on print settings but stronger is better. I use ASA for a lot of car parts I do but for these I used PLA since they're hidden and won't really see any direct sunlight. I did not need to use any support.Remove whatever portion of the broken clip/screw holes are still on the dash piece. You want to try to smooth out the surface so it matches the surrounding area, but don't worry about trying to get it perfect. Make sure nothing protrudes drastically above the surface or the new printed parts won't fit well.Sand the areas where the new 3D printed parts will go with a low grit sandpaper. The roughness will help the glue stick better. I used 400 grit but it doesn't really matter. You just want some scratches in the surface for adhesion.Glue the replacement parts to the dash. Alignment is pretty much done by eye. The screw hole replacement part is pretty easy, just drop it into the bottom of the valley and move it left and right to align with the screw holes. The clips at the back are a little more difficult. On mine I could still see where the original clip had broken/was removed and I was able to align to that. I used Loctite 4311 but a thicker two part epoxy would actually probably be a better choice and much cheaper. Be sure to clean the area and wipe it down with an alcohol pad before gluing.