SR Suntour fork top cap socket (FAA122 replacement)

cults3d

I recently attended bike tech workshops through the Professional Bike Mechanics Association (PBMA) where I received training in a wide range of different things from many different brands. I was constantly thinking, "I can definitely 3D print that," and this is just one of several things I'll be posting which were inspired by these seminars. SR Suntour makes a variety of forks, but most people have seen their forks in the form of heavy steel forks like the XCT, which are commonly found on many entry-level bikes, mountain bikes, hybrids, etc. I previously thought that these forks were pretty low quality, but that's not fair or accurate. It turns out they're inexpensive, yet they also have some brilliant features that make them completely serviceable. In particular, the design of the bushings is excellent - they can be removed with a screwdriver and quickly replaced. To do this maintenance, you need the FAA122 tool, which I've included in the photos. Considering the FAA122 is plastic, I immediately saw the possibility of printing one, and at that point, turning it into a socket seemed like the obvious way to go. The torque spec on the socket is only 10 Nm, and with so many points of engagement on the splines, this tool can handle that easily. I could probably even print it with a 3/8" socket drive without issues, but the 1/2" is stronger as it spreads the drive forces over a larger radius, thus reducing the stress on the socket. I want to thank Jon Wells of Envelo for his help in this project! A Fusion 360 F3D file is included if you'd like to make any changes.