Senseo lever replacement (Model HD7827/52, part 422224763081)

thingiverse

The pivot points of the lever on my Senseo machine snapped off. My model is HD7827/52, and I'm stuck with buying a replacement part 422224763081 for $10. I decided to hack together a fix by reverse-engineering the lever, not exactly, but it works decently well. Printer Settings Printer: Vertex k8400 Rafts: Yes Supports: Yes Resolution: 0.15 Infill: 25% Notes: There are two files: one has a complete body, and the other has an opening in the middle to save materials and printing time. Printing Time: +/-2h PLA On my print, the support material was difficult to remove. So I had to sand the surface. This resulted in a rough but grippy surface. Using black filament would be a good choice, but I only had grey PLA available. You could print it standing up, but then the printing time increases to +4h Post-Printing This is an instruction on disassembling (on pictures with the printed part already installed) reassembling everything is exactly the same thing but in reverse. Step 1: Opening the Head Use a flathead screwdriver on all four points to open up the head of the machine. Start with the two points closest to the hinge Step 2: Removing the Lever from the Lid The lever should come down when one of its pins comes loose. You could always use a screwdriver, but be careful now. The entire locking mechanism comes loose from the lid. A good tip is to free one pin first and then the other. Step 3: Decoupling the Arm Using two fingers, you can squeeze the arm to free the pins from the lever. Be careful not to break them off. A good tip is to free one pin first and then the other. Step 4: Reassembly Now you can take the new part and do all the above in reverse order. Make sure when back in step 1, put in the side away from the hinge first. Then close the lid halfway to push in the last two points. This is because of the stoppers that prevent the lid from opening too far. You're done! Time to take a break and drink your coffee How I Designed This I took two pictures from the top and right side of the lever (with a ruler as scale) These were imported into Solidworks and scaled correctly. Tracing the outlines gives the correct basic shape. Measuring important dimensions from other features left me with a useful part