bmartin
Posts: 17
Joined: Thu Dec 31, 2015 1:55 pm
Delivery Date: 20 Jun 2015
Leaf Number: 2012

3D printed brake fluid cap

Mon Oct 24, 2016 9:40 pm

I wanted to share this with everybody for the sake of lost fluid caps of the future.

I was adding more brake fluid today and accidentally dropped the cap below the motor. Being as there is a solid floor, it didn't hit the ground but instead ricocheted off the floor presumably never to be seen again.

In a panic, I went to Tinkercad and designed a new cap. After some modifications and good measurements, I created a cap that seals on tight and is designed to fit the threading of the Leaf. No idea if this will fit other vehicles, or even if it will do the job correctly, but hey, $13 I don't have to spend.

And here's the final product: https://www.thingiverse.com/thing:1848415/

Image
2012 Nissan Leaf SV - Purchased June 2015 with 16.2k miles.
Lost 1st bar 09/2016 at 37.7k miles, 84% SOH
01/01/2017 - 41k miles, 86% SOH, 226 GIDs

Projects:
Happy Leaf Bluetooth ELM app
Carwings Siri Intigration
Leaf Underglow/charging port lights

powersurge
Posts: 723
Joined: Wed Oct 21, 2015 10:24 am
Delivery Date: 06 Dec 2014
Location: Long Island, NY

Re: 3D printed brake fluid cap

Tue Oct 25, 2016 6:53 am

It is amazing that we can do this stuff. Is this made of plastic? If so, what kind of plastic?

desiv
Posts: 588
Joined: Tue Jan 06, 2015 1:10 pm
Delivery Date: 04 Jan 2015
Leaf Number: 018850
Location: Lincoln City, Oregon

Re: 3D printed brake fluid cap

Tue Oct 25, 2016 2:51 pm

As long as it doesn't get too hot under the hood (I'm not sure.. No idea what temps are under there), PLA should work fine.
I think it's OK to about 122 degrees Fahrenheit before it starts to soften..
Otherwise ABS or PETG should be better choices...

Downloading that model just in case.. ;-)

desiv
2012 SL - Silver

Firetruck41
Posts: 501
Joined: Sun Aug 09, 2015 10:36 am
Leaf Number: 408264
Location: SW Washington State

Re: 3D printed brake fluid cap

Tue Oct 25, 2016 6:30 pm

Great job and great idea, my only concern is that with brake fluid, the primary concern is moisture, so I assume the original cap has a rubber or silicone seal built in. Brake fluid is hygroscopic and absorbs water from the atmosphere. Without that same type of seal, I would not want to run it long term.
8/2015- New to me 12bar 2013 SV w/QC package and 37k miles

RockyNv
Posts: 204
Joined: Mon Sep 19, 2016 10:35 am
Delivery Date: 17 Sep 2016

Re: 3D printed brake fluid cap

Wed Oct 26, 2016 1:50 am

Other concern is that brake fluid is a great solvent and tends to turn some plastics brittle or to putty. Its one super paint remover too.

There is of course also the $2,600 + cost of the MakerBot Replicator 2 and the filament costs that kinda detracts from the economy of it all. For an emergency to get by until you can get an OEM approved cap formulated to withstand long term use with brake fluid that's a pretty good idea.

arnis
Posts: 726
Joined: Sat Jan 23, 2016 3:21 pm
Delivery Date: 23 Jul 2014
Leaf Number: 015896
Location: Estonia, Europe

Re: 3D printed brake fluid cap

Mon Oct 31, 2016 5:22 am

This solution is not acceptable. Brake fluid will absorb moisture if left in open air.
Replace the cap. If you have waited for weeks you have to flush the fluid too.
Short range EVs <30kWh -- Medium range: 30-60kWh -- Long range: >60kWh
Charging: Trickle <3kW -- Normal 3-22kW -- Fast 50-100kW -- Supercharging >100kW

bmartin
Posts: 17
Joined: Thu Dec 31, 2015 1:55 pm
Delivery Date: 20 Jun 2015
Leaf Number: 2012

Re: 3D printed brake fluid cap

Fri Nov 18, 2016 5:28 pm

powersurge wrote:It is amazing that we can do this stuff. Is this made of plastic? If so, what kind of plastic?

I use PLA in my printer. I think technically it is a corn starch, bioplastic if you will: https://en.wikipedia.org/wiki/Polylactic_acid

Firetruck41 wrote:Great job and great idea, my only concern is that with brake fluid, the primary concern is moisture, so I assume the original cap has a rubber or silicone seal built in. Brake fluid is hygroscopic and absorbs water from the atmosphere. Without that same type of seal, I would not want to run it long term.


This is a good idea, I didn't think about moisture. I will spray the bottom of the cap with something like this (Flex seal): https://www.amazon.com/Permatex-82099-S ... B0018PW15I
2012 Nissan Leaf SV - Purchased June 2015 with 16.2k miles.
Lost 1st bar 09/2016 at 37.7k miles, 84% SOH
01/01/2017 - 41k miles, 86% SOH, 226 GIDs

Projects:
Happy Leaf Bluetooth ELM app
Carwings Siri Intigration
Leaf Underglow/charging port lights

arnis
Posts: 726
Joined: Sat Jan 23, 2016 3:21 pm
Delivery Date: 23 Jul 2014
Leaf Number: 015896
Location: Estonia, Europe

Re: 3D printed brake fluid cap

Fri Nov 18, 2016 5:35 pm

Too late. Hope this chemical will not be dissolved with DOT fluid.
Otherwise you might ruin something much more expensive than that cap.
Also I hope that super-cap has has specified maximum pressure rating.
Short range EVs <30kWh -- Medium range: 30-60kWh -- Long range: >60kWh
Charging: Trickle <3kW -- Normal 3-22kW -- Fast 50-100kW -- Supercharging >100kW

derkraut
Posts: 1493
Joined: Fri Jul 16, 2010 7:39 pm
Delivery Date: 14 Jun 2011
Leaf Number: 004248
Location: San Diego vicinity

Re: 3D printed brake fluid cap

Sat Nov 19, 2016 8:31 am

Is the brake fluid reservoir under pressure? I don't think so???
Derkraut
Color: Cayenne SLE, ETEC trim
reserved: 5/15/2010
Leaf del. 6/14/2011
New Traction battery installed on 7/28/2017: 12 bars @37.4K+mi. 100% charge: DD readings: Bat temp 81.3F, Gids=283, S=94.1, C=66.13, H=99.79 394V :)

arnis
Posts: 726
Joined: Sat Jan 23, 2016 3:21 pm
Delivery Date: 23 Jul 2014
Leaf Number: 015896
Location: Estonia, Europe

Re: 3D printed brake fluid cap

Sat Nov 19, 2016 10:41 am

Everything in our atmosphere is under pressure.
What you ask is: "is there a pressure difference between two sides of cap".
If there would be absolutely no pressure then air moisture would just ruin brake fluid.
Short range EVs <30kWh -- Medium range: 30-60kWh -- Long range: >60kWh
Charging: Trickle <3kW -- Normal 3-22kW -- Fast 50-100kW -- Supercharging >100kW

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