Shimano Brake Lever Replacement

thingiverse

This is a simple and effective fix for broken shimano levers of all types. The Lever is made from two aluminium plates which sandwich the original lever adjuster. The 3D printed centre is then clipped over these, providing an ergonomic and customisable brake lever. As per my profile I am an keen on providing high performance replacement parts, using my engineering background. I have used this lever for the past 6 months, I have ridden loads (at least 500 miles) including trips to Bike Park Wales, Forest of Dean etc. I have also had more crashes than I would like to admit but the lever is still in great condition with no issues. I have not had to replace any parts since fitting it. I wanted to create a 3D printed lever replacement as I have broken several shimano ones in the past. However, I was concerned about their strength and reliability over time. I also wanted to re-use the reach adjustment that is normally replaced along with the lever (Rather Wastefully) even if it is undamaged. This lever is also ambidextrous and can be used on either a RHS or LHS body. This lever is as strong as a shimano one due to it's use of 2 aluminium sheet arms . The 3D printed part of the lever only acts as a cover that transmits pressure into the arms. As the arms are not directly connected the lever tolerates shear forces without deforming and is resilant during crashes. When pulled the lever is very stuff and stable, equal to the original. The metal lever arms are made from 1.5mm thick aluminium sheet. This was laser cut for me at a university but can be sent to a company such as sendcutsend or equivalent. I had several made at once for any future replacements. I am happy to film an installation video if anyone is interested * note that this was designed and tested on a Shimano SLX M7100 Lever, all of this generation use the same design so I believe this can be fitted to all current models from XTR to MT200 - however the space between the metal arms may vary and the depth between the slots in the print may need to be adjusted to account for this.