Vibroplex Bug key knob and paddle replacement

thingiverse

I accidentally broke a crucial part on my vintage 1963 Vibroplex Original Deluxe, which I purchased new back in 1963 and still cherish as my first bug. Recognizing that many ham radio enthusiasts continue to rely on bugs, just like me, I realized this could happen to anyone. So, I decided to design replacement parts using Fusion 3D. This post is the direct outcome of that experiment, and fortunately, my initial measurements were precise enough for a seamless fit. To assemble the new paddle piece, you'll need to tap an SAE 8-32 hole into the knob and cut a 15 mm length of 8-32 threaded rod or shorten a longer screw to create "All-Thread" for the mounting screw. It would be easier if you filed away 5mm of threads from the end of the screw, leaving 4-5 mm exposed at the knob's edge to secure it properly. For optimal results, use at least 20% infill and ideally 50% on the paddle piece for added strength. If aesthetics matter, aim for a .12 resolution setting for the best appearance.