SAITEK RADIO PANEL REPAIR

[Steve Horsfall]

Recently one of the Outer knobs on the Saitek Radio Panel stopped rotating 360 deg, only about 180 deg. I did not put force on it as it felt like it was going to break. I disassembled the panel for inspection ( WARNING - YOU CANNOT REMOVE THE KNOBS FROM THE OUTSIDE, THEY ARE HELD IN PLACE BY LOCKING COLLARS).
Dis assembly is a bit trickey. When finnaly pulled apart, I found that the Outer knob has a COG that rotates the shaft of the rorary switch with a smaller COG. The large COG was split with not much face to re glue.I decided to try to make a replica using Fusion 360. After many hours of design and printing 3d drafts I got a cog that works.

Replacement Cog.jpg

A bit rough but fits on the shaft and works, all 24 teeth mesh OK and the knob feels normal.
Now I will try to make replacement FIP knobs.

[Reinhard]

Is also broken with me. I would buy a bike from you.

Greetings Reinhard

[Steve Horsfall]

Hi Reinhard, My intention was to attach the G code file in the forum to enable any person with a 3D printer to use. This type of file cannot be attached to the Forum. I was able to e-mail the file to a friend and it worked ok. If you have access to a 3D printer I should be able to e-mail the fie to you.

[thedazman]

I’ve replaced all 22 knobs on my 11 FIPs with 3D printed ones.

The issue with doing fip dials is the 2mm post which 3D printing can’t cope with very well.

I use a 2mm diameter steel rod to push into the rotary and have 3D printed knobs with a 2mm hole to take the steel shaft projecting out of the fip and I secure with a 4mm grub screw. For the knobs that aren’t broken I simple printed a sleeve to fit over the existing knobs and made them twice the diameter as the original and feel so much better.

I love a bit of fusion myself

Daz

[Steve Horsfall]

Hi Daz, How do you stop the shaft from pulling out of the FIP, is there an inside collar?

[Oz Flyer]

Hi Steve, Did you use the gear tool or did you do teeth your self?

[Reinhard]

Hi Steve, unfortunately I don't have access to a 3D printer. I would reimburse you for the costs.

[Steve Horsfall]

@Oz Flyer, Painfully I did the teeth myself, did not know that there was a gear tool, I will have another look at Fusion. 73s

[Oz Flyer]

Steve,

If you have not seen this channel I do recommend it.
https://www.youtube.com/channel/UCo29kn ... ZGZ50VKvWA

[Oz Flyer]

Steve,
I think this is the one I looked at.
https://www.youtube.com/watch?v=ZakT54JIhB8

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