3D Printed Clutch Lever Boot Replacement for 1963 Volvo Wagon
Neil Glasson (PhD, Mechanical Engineering) is a Senior Research Engineer for a New Zealand government agency. In his free time Neil is also a 3D printing and classic car enthusiast.
Neil had to replace the rubber boot around the clutch lever of his 1963 Volvo Amazon wagon. Purchasing the replacement part required an overseas purchase and at least a one-week lead time.
Placing the dimensions into Solidworks, he was able to design and print a new part on the first pass with his Prusa Mendle i2 printer.
One of the important fit challenges was creating a tight seal around the lever shaft. He also needed to consider still having room to stretch the boot over the wider top of the lever. With the help of liquid soap, the flexibility of NinjaFlex filament allowed the part to stretch into place and fit snugly around the lever.
Since the part was replaced, Neil has added several thousand kilometers to his odometer, and the part has held up beautifully.
“I’ve put a few thousand km on the car since and it is all good.” – Neil GlassonSHOP NINJAFLEX »
The original rubber flexible boot that fit around the clutch lever became hard and cracked over time.
LAYER THICKNESS: 3 perimeters