[C5 X7] 3D printed keys for HP24W halogen DRL replacement

[the-termin8r]

All pre-facelift X7 owners know the pain of replacing the DRLs. The least-worst way to do this is with a T45 key and some BluTack, but you risk either dropping the key (like I did twice) or the bulb into the bowels of the car. I got fed up of this, so I decided to design some keys to help the process. The mode of operation is pretty much identical to the T45 method except these mount permanently and are easier to use. Unfortunately, you do still need 17 elbows and an arm amputation, that can't be fixed with a simple 3D print.

Some quick notes on the design:

- Designed to friction mount, but can be secured with a couple of drops of superglue
- Designed to mount permanently, but can probably be reused (though I don't recommend it)
- Bypass hole built in so that a T45 can still be used should the part fail
- I'd recommend printing these in something tougher than PLA, like ABS or PETG. I printed mine in PLA, so time will tell how well they hold up (not great is my guess).
- STL files for printing included
- IGES files for design modification included
- Basic documentation included

[GiveMeABreak]

Where were you 8 years ago when I did mine??? Beats my string round the wrist tied to the torx tool!

[the-termin8r]

I tried a similar method of zip tying the T45 to my ESD strap, but it just slid off the zip ties. LOL

[GiveMeABreak]

I just found that post....

https://www.frenchcarforum.co.uk/forum/ ... 87#p464087

Those were the days...

[wheeler]

Once you do it the first time put a smear of silicone grease on the O rings & in the housing & they normally come back out easily the next time around.
Great idea though, how long does something like that take to print?

[the-termin8r]

Print time for a pair is about 2h 50m with my setup. Time will obviously vary with slicer settings.

[steveclv]

It's amazing how useful a 3D printer is! I have designed and printed quite a few "handy bit's" using Tinkercad which is a doddle to use. These would have been so useful when I replaced mine - but I put LEDs in so hopefully never have to do them again.

[Stickyfinger]

You can take off and refit the front bumper in less than 30 mins....

[the-termin8r]

Just a quick update, I went to pull off the prototypes and the friction mount failed. It would seem that once the gasket has been mounted for long enough it has greater friction to the headlight housing than the key to the bulb. I'd thus definitely recommend gluing the keys to the bulbs. Other than that, I also suspect that because I printed in PLA, the prongs have fatigued a little bit. Nothing serious though. I'd say you can get around it by printing in ABS or PETG and at 100% infill as opposed to 20%. I'd update the OP with this, but can't seem to.

EDIT:
I've attached the revised instructions. All other files remain the same.