S14 Zenki headlight adjusters (replacement?)

[omgosh]

This little gear piece on my headlight adjusters broke. Has anyone ever fixed these before? Perhaps there is another Nissan that uses this type of headlight adjuster? I already tried superglue lol.

http://img.photobucket.com/albums/v337/omgosh/20160114_002638_zpsktizxmcn.jpg

[rawgarage]

Is there that much of a difference to adjust

[omgosh]

Indeed there is, especially because I accidentally adjusted the passenger headlight all the way to the right before it broke.

I suppose I could just take the headlights out and aim them with pliers or something but maybe there is a better way..

[Drift_86]

Customize some projectors, there's no way in fixing the headlight now.

[omgosh]

Welp, after extensive googling I finally found this...

https://www.tinkercad.com/things/byNo10fLWB6/t725.png?t=504afc12
https://www.tinkercad.com/things/byNo10fLWB6-nissangear

So I shall see if I can get one made to try it out.

[rawgarage]

^ just buy a headlight

[SoundEfx]

A friend who owns a 3D printer would come in handy right about now.

See if someone would make one for you.

[Kuma]

do you have a pic of the broken part on the headlight? no way to notch it and use a flat head to adjust it? or even a pair of needle nose? worst case scenario, you might be able to use washers behind the mounting points as shims to get it back in spec. this is why you shouldn't screw around. you kids screw around too much.

[silviaks2nr]

3d print hex heads and epoxy them directly to the back of the adjustment stud. Then you can remove all the gears and linkage. I do this for zenki retrofits when everything is broken, which it usually is. In a pinch you can pry the gear off the stud and grab it with vise grips and turn it.

[omgosh]

this is why you shouldn't screw around. you kids screw around too much.

Hey, If I was just some kid screwing around, I betcha I wouldnt be trying to fix such a trivial issue.

3d print hex heads and epoxy them directly to the back of the adjustment stud.

Yeah, thats kinda what I was thinking if I wanted to rig it..it would be easier to just tap the stud and double nut it though. The other idea was to epoxy extra 4-5mm 1/4 inch drive sockets on them lol.


Anyway, I gave my buddy that CAD file and he says he will be printing me a few tomorrow to try out!

[Aureus Mente]

Living in the las vegas desert heat my adjustment gears turned to dust. I swapped on clear headlight covers for my zenki and was curious why my headlights were so off (one pointing directly up and one straight at the ground). Took them apart and my adjusters just crumpled in my hand. I am assuming this is going to be the problem for all oem zenki headlights. If your printing some out message me i will pay for the time and effort for a few sets.

[ADIDASilvias]

I printed mine out of ABS. So far they work well enough, but I don't know how durable they will be in the long run. Although once I get them set I won't really need to touch them. I retrofitted HIDs for the low beams but still need adjustment for the high beams, which is why I replaced them. I searched high and low for an option to buy some online, but I couldn't find any with the right dimensions.

The hardest part about printing them is that you can't print the splines so you have to print a slightly smaller hole and press fit them on the shaft. Most likely they will eventually strip out like the nylon stock gears, but if they do I'll just print some more.

I thought about getting some nylon and printing them, but it's hard to get high temp filaments to stick to the print bed even with the bed temp raised. If I had a closed print chamber and some kapton tape it would be much easier.

[omgosh]

Yeah I didnt bother to print the hole, just made it solid so I could drill it a bit undersize and epoxy it. Here is the prototype we made...whenever I get around to drilling and installing it to see if it works I may get a few more made.

http://i.imgur.com/N7R01ux.jpg

[ADIDASilvias]

Nice work! What material?

[silviaks2nr]

looks like PLA

[SoundEfx]

Seeing that these tend to break, are you going to start selling them?

[omgosh]

Not sure on the material. It is pretty hard, harder than ABS it seems. It was some spare stuff my friend had at work...they use it to make dental trays for impressions or something like that.

As far as selling them, probably not...unless I get bored enough to try making a mold or something. I can only print a few more since its not my machine.