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SAITEK RADIO PANEL REPAIR

Posted: 07 Apr 2020, 05:47
by 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. :roll:

Re: SAITEK RADIO PANEL REPAIR

Posted: 07 Apr 2020, 14:24
by Reinhard
Is also broken with me. I would buy a bike from you.

Greetings Reinhard

Re: SAITEK RADIO PANEL REPAIR

Posted: 07 Apr 2020, 23:23
by 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.

Re: SAITEK RADIO PANEL REPAIR

Posted: 08 Apr 2020, 02:33
by 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

Re: SAITEK RADIO PANEL REPAIR

Posted: 08 Apr 2020, 03:08
by Steve Horsfall
Hi Daz, How do you stop the shaft from pulling out of the FIP, is there an inside collar?

Re: SAITEK RADIO PANEL REPAIR

Posted: 08 Apr 2020, 07:07
by Oz Flyer
Hi Steve, Did you use the gear tool or did you do teeth your self?

Re: SAITEK RADIO PANEL REPAIR

Posted: 08 Apr 2020, 16:06
by Reinhard
Hi Steve, unfortunately I don't have access to a 3D printer. I would reimburse you for the costs.

Re: SAITEK RADIO PANEL REPAIR

Posted: 08 Apr 2020, 22:32
by 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

Re: SAITEK RADIO PANEL REPAIR

Posted: 09 Apr 2020, 00:06
by Oz Flyer
Steve,

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

Re: SAITEK RADIO PANEL REPAIR

Posted: 09 Apr 2020, 00:21
by Oz Flyer
Steve,
I think this is the one I looked at.
https://www.youtube.com/watch?v=ZakT54JIhB8

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