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My King Song S22 3D Printed Accessories


Rawnei

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Nice! Thanks for sharing—someday I'll be *forced* to get a printer.

Unrelated question: why do your headlight covers look upside down? The louvers are opening up, I would expect them to be open on the bottom, you know, like the bill of a cap?

Edited by Tawpie
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5 hours ago, Tawpie said:

Nice! Thanks for sharing—someday I'll be *forced* to get a printer.

Unrelated question: why do your headlight covers look upside down? The louvers are opening up, I would expect them to be open on the bottom, you know, like the bill of a cap?

Not sure what you mean, the headlights are S22 stock not modified.

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23 minutes ago, Rawnei said:

Not sure what you mean, the headlights are S22 stock not modified.

Thanks for sharing. Do you also plan some cover for lights? this is what troubles me a lot. Its a weapon, not a light on shared ways.
(or any tip how can be the dimming change by me in firmware, which could be the best way)

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2 hours ago, Miko.cz said:

Thanks for sharing. Do you also plan some cover for lights? this is what troubles me a lot. Its a weapon, not a light on shared ways.
(or any tip how can be the dimming change by me in firmware, which could be the best way)

Do you mean lights blending? For blending I saw someone made something and shared it on telegram I have yet to test that solution though, not sure how effective it would be.

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10 minutes ago, Rawnei said:

Do you mean lights blending? For blending I saw someone made something and shared it on telegram I have yet to test that solution though, not sure how effective it would be.

Im not sure, "blending" is something different in my native language.
My target is to reduce glare of anyone comming in the opposite way (riders/bikers/pedestrians... which I must pass), but I would still like to "be seen" and also see something (5W should be enough). Buy another independent lights is the last option.

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26 minutes ago, Blunzn said:

That is the one I saw, I think it would maybe require a more heat resistant material but not sure.

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45 minutes ago, Rawnei said:

That is the one I saw, I think it would maybe require a more heat resistant material but not sure.

definitly a good idea.

or some sort of case/frame for putting them in/out fast. the outer part would be cool enough to hold the 'plugs' in place even if they deform a bit. then attach in to a nearby screw as safeguard. for riding with full brightness you just rip them off the light (ofc the tangeling tpu parts shouldn't interfere with the tire or fender). when you need em just sit down and put them back in.

maybe some aluminium foil on the underside of the plugs to increase/redirect more light downwards if needed. 

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I'm working on a headlight bumper, will see if I can incorporate something like that in the design, no promises need to be carefully tested also.

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7 hours ago, Miko.cz said:

Thanks for sharing. Do you also plan some cover for lights? this is what troubles me a lot. Its a weapon, not a light on shared ways.
(or any tip how can be the dimming change by me in firmware, which could be the best way)

I took the lights apart as an experiment to install black tape on the lower third of the lenses just below the led diode. Put them back together and resolved the glaring problem. The black tape absorbed quite a bit of the light but works great. 
My next move will be to remove the black tape and spray the bottom portion with chrome paint. Giving it a much brighter reflection. 

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10 hours ago, Rawnei said:

Not sure what you mean, the headlights are S22 stock not modified.

Haha. My ignorance is showing. I had 'assumed' that the plastic cover would shield the top only, and not the top and bottom. Silly me. :efeec46606:

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9 hours ago, Rawnei said:

New part:

  • King Song S22 Sliding Mechanism Dirt Protectors

https://www.thingiverse.com/thing:5454456

There are multiple problems with the original design of the King Song S22 sliding mechanism for the suspension system:

  1. This type of design has problems with friction as the interacting parts and forces involved causes a lot of resistance making the suspension very stiff
  2. Problem gets worse over time as dirt accumulates in the channels
  3. King Song has installed rubber parts on the rails that is supposed to help keeping dirt out but they add a lot of resistance by themselves (this part is not a stopper! It's purpose is only to prevent dirt)
  4. King Song has put grease in the channels which will accumulate and retain dirt

This print is a "simple" solution that will not solve the problem but will help making the sliding mechanism better and less dirt prone, this is an iteration of an original design/idea that circulated on Telegram (author unknown), I have taken the original design and re-created the models in Fusion 360 but with better tolerances (less stiction) and also added a new part that goes around the rails itself for even more dirt protection.

For this print you also need some PTFE dry lubricant, personally I use WD-40 Specialist PTFE Dry Lubricant as it comes with a long nozzle making it easier to reach and apply.

7.thumb.jpg.b1cc1a08d021f1cd94c4e7c0a7af8639.jpg

 

Does anyone have a recommendation on what material and process to use to print these parts, and which company to order them from? I don;t have time to get up to speed on 3D printing currently and would appreciate anyone's advice. Thanks!

I uploaded all three .stl to Hubs.com and selected Industrial SLA for the process. The choices under 3D printing were MJF, SLS, SLA, Industrial SLA, FDM, and Idustrial FDM.

Two of the parts passed automated inspection but S22_Top_Slider_Protector.stl came back with geometry errors.

 

Screen Shot 2022-08-09 at 2.04.15 PM.png

Screen Shot 2022-08-09 at 2.06.24 PM.png

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SLA is (or was) pretty expensive but it's very pretty (fine details, easily finished surfaces)... FDM is the process 'home' printers use (squeeze toothpaste in a line). @Rawnei indicates TPU 95 in the thingiverse listing for the dirt cleaners.

Have you asked around your rider community? Printers are pretty common amongst riders... I'm gonna hit up my local hobbyists.

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45 minutes ago, Tawpie said:

SLA is (or was) pretty expensive but it's very pretty (fine details, easily finished surfaces)... FDM is the process 'home' printers use (squeeze toothpaste in a line). @Rawnei indicates TPU 95 in the thingiverse listing for the dirt cleaners.

Have you asked around your rider community? Printers are pretty common amongst riders... I'm gonna hit up my local hobbyists.

 

No other riders nearby, and no local 3D printers available.

@Rawnei are all parts designed for FDM and TPU?

 

Looking at the models, I'm guessing regular FDM would be fine for the Inner_ and Outer_Slider_Protectors?

For FDM, the material choices are PLA, ABS, PETG, TPU and ASA. If any of these are selected, the specific type of material available is "prototyping" (PLA, ABS, etc).

The next two parameters are Infill (20, 30, 40, 60, 80%) and layer height (100, 200, 300μm) (defaults in boldface).

 

For the S22_Top_Slider_Protector (aka "dirt cleaner"?) maybe Nylon based on Industrial FDM would be better to achieve higher tolerance and reduce friction.

For Industrial FDM, the material choices are Nylon, ABS, ASA and PEI. The specific type of material available is different for each, eg, for Nylon the only opition is Markforged Onyx.

The next two parameters are Infill (Ultra-light, Light, and Solid) and layer height (100, 180, 200, 330μm) (defaults in boldface).

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You know what, I'd suggest getting in touch with @RockyTop. He's a successful print-for-hire rider—I have his stands and he's made some other parts for me. Top notch quality, excellent to do business with. He has an eBay store, Black Crow stands. He'd know everything that's needed, and I'm certain would be reasonably priced.

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26 minutes ago, Tawpie said:

You know what, I'd suggest getting in touch with @RockyTop.

Thanks for your input and calling out @RockyTop.

I believe this discussion will be of broad interest to the community, so I am keeping it public. If the mods want to split it off into a separate thread that's fine.

The S22 slides have been a hot topic and no doubt others will want to replace theirs.

It would be nice to get input from @Rawnei and others.

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