If anyone is considering taking on a project in similar fashion to robricc (sleds), Firefox (buttons) and Webroach (front panels), I would like to suggest replica handles in the original pattern.

Although I still have a reasonable amount of remaining stock, it is decreasing steadily as people break them. People are continuing to break them in the same way - wrench on the handle as hard as you can when the unit sticks in the sled (yeah, right) without investigating what the problem is first. As a piece of general advice - if it comes to a choice between risking a broken handle pulling out a jammed unit, or having to dismantle the entire dashboard to release the sled and unit, Dismantle the Dash.

Although a great deal of other unit casing material (cases, lids, sleds, front panels, buttons, hinges, springs, screws) is here in stock in sufficient quantity, this one is not. It is the most difficult one to reproduce, and although panels, buttons and sleds are underway, there is no directed effort for the handles. I know Webroach is producing them, but it is as a limited by-product of the panel effort, and is likely to be difficult (and costly) to deliver handles separately from the panel.

I would say that at the current rate of consumption, it is likely that original handles will disappear by the end of this year (2005) at the latest.

... sound of everyone rushing to email "broken handle" sob stories to Rob now commences..

Perhaps photo evidence might be a prerequisite for a handle "parts" order.. ?

Cheers

On a side note, does anyone have a fix for the handle "rattle" ?

New springs.

Or mod the mounting position of the old springs.

To be honest, I have always found that simply tightening the main hinge screw slightly on both sides sorts this out by making it pivot a little more stiffly. The screws themselves gradually tend to unscrew themselves over time.

Be aware that the bottom two screws on each side loosen at the same rate as the main one, so if you discover that the top hinge screws are already loose, do them all up at the same time, or locktight the lot of them (blue/non-permanent loctite). You will need jeweller's screwdrivers, size 0 and 1. Don't use the size 1 on the bottom screws (which are smaller) as you will damage them.

If all the lower screws come out, then the handle is no longer supported correctly and will twist unevenly around the pivots. This will cause the handle to break, eventually.

I can mention it to the casters and machine shops that I've been speaking too. Should be simple to plaster cast. But I wonder if the metal buttons are machined, maybe they could fill the space within the U-shape of the handle, thus reducing waste. 10 buttons in the space of one handle U-shape might be a good use of metal.

[Edit: added]
Or, a long U-shaped metal extrusion could be created. It could be sliced into many handle shapes, each milled to perfection. I'll also run this idea by the metal shops.

I just need a CAD file for the handle. My trusty plastic grade school ruler might be a little less than accurate to create the CAD by hand.

If someone at Rio can be bothered to dig out the archive of my former home directory, they can find the appropriate CAD in ~rob\empeg\Projects\Rio Car\Fascia (or somewhere nearby). I heard my files are now archived offline which is sad, as that's a big chunk of empeg's legacy. GPL the lot of it I say!

The Mk.2 handles were cast using a lost wax process. If anyone is thinking of doing this again I strongly recommend against doing so - it was an utter nightmare! Machining would surely be the best option for a small run (but it's not the easiest part to machine - much easier to do in three pieces like the Mk.1).

Rob

I think you are going to find that the least expensive option is to just waste the stock.

Not in CVS (the mk1 drawings are though ). I'll see what I can find, Mike's probably got the offline stuff burned to a DVD or something, it doesn't appear to be online on the servers.

Hugo

I have a shop looking at making the handles(again).
A couple ideas were brought up.
To save some cost they could eliminate the machining in the handle for the 2 plates on either side with the "hooks" that hold the player into the sled.
It would still rotate and pull the unit out but it wouldn't lock the player in.
This doesn't appear to be a problem on my player as it feels secure enough without it.(I've tested it for a week and it hasn't come out,the docking plug seems to hold in in nicely)
If needed a piece of velcro could be added to the back of player and inside of sled(if enough clearance) to hold it in.
The other issue is that there would be no more spring to keep the handle from moving or vibrating.Perhaps a small piece of velcro here would work also.
So would people prefer to have the exact handle or a somewhat modified handle to save on costs.

Don't forget that the hinge piece carries two holes for two extra screws on each side for re-inforcement. I have no idea about how just a "single screw" version would affect the case ear for the hinge: I would suspect that you would be driven nuts by the handle rattling without the springs.

Maybe if you offered both options (with/without) you could let people choose?

If anyone is going through the MKII CAD files, could you please make me a copy of the "Button Base Part.SLDPRT"? The metal button project is stalled without it.

With handle CADs, I could have these made. Without the CADs, it'll just take me more time, but I'll still try.

You have PM.
-Zeke

If you remember I made a replacment handle when I re-did the face but we just didn't get enough instrest to cover the run cost. I am sure someone can post the link to the photos I posted,

I never broke a handle but I could see how they could break.