"B" Post Caps - How many need replacements?

[Brit-Car-Nut]

(Just adding and updating)

I am looking into having the tooling made to reproduce the "B" Post caps used on the M100.
I am aware that there are two styles with different hinge designs and I hope to offer both styles.
Can you please let me know if you are interested in a PAIR and if you require the early or later design.
If you don't know which design you need, here are some pictures:



Early Style on the left and Later Style on the right

The later style uses an embedded hinge that is pop-riveted at the two holes. Right now those are not available, so you will need to re-use your existing hinges.
I will look into finding a source for those too, but right now, I need to know if there is enough demand to run this project.
This is a non-commitment list. You are under no obligation to buy but without knowing the demand, I can't decide how many to make and how to price them.
NO MONEY will be collected until the parts are ready to ship and will most likely be posted from both the US and the UK.
I want them to be as affordable as possible and that becomes a reality when we spread the total cost across the most sales (Like the escutcheon project).

The goal is to keep the price per pair below £30.00 (It pays to read all of the posts...)

Please join in:

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later?
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40.
41.
42.
43.
44.
45.

If you don't know how to join, just reply saying you want to be included and I will add you.
If you want more than one set, add your name multiple times. It makes the math easier later on.
Thank you.

[Monty]

Please join in:

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later?
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41.
42.
43.
44.
45.

If you don't know how to join, just reply saying you want to be included and I will add you.
If you want more than one set, add your name multiple times. It makes the math easier later on.
Thank you.

[harvey]

early set for me please. good luck with all your efforts

harvey

[Axel-F]

Great idea !
One later set for me please !
Thanks !

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later?
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43.
44.
45.

[housam]

I require a set of early type too. Count me in!!!!

[Brit-Car-Nut]

Some News and Progress:

We have gotten 3D drawings and after a lot of discussions with the manufacturer's engineers, the mould is being made.
We hope to have samples within the next 30 days, unless something goes wrong or doesn't work out like we expect.

Nudge your friends, neighbors or even your enemies as this WILL be a one time offer and once the production run is finished, doing any more will be not financially justifiable.
The more of you that buy the caps, the lower the price will be for everyone. We hope to have pictures very soon after receiving the samples.


I am looking into having the tooling made to reproduce the "B" Post caps used on the M100.
I am aware that there are two styles with different hinge designs and I hope to offer both styles.
Can you please let me know if you are interested in a PAIR and if you require the early or later design.
If you don't know which design you need, here are some pictures:



Early Style on the left and Later Style on the right

The later style uses an embedded hinge that is pop-riveted at the two holes. Right now those are not available, so you will need to re-use your existing hinges.
I will look into finding a source for those too, but right now, I need to know if there is enough demand to run this project.
This is a non-commitment list. You are under no obligation to buy but without knowing the demand, I can't decide how many to make and how to price them.
NO MONEY will be collected until the parts are ready to ship and will most likely be posted from both the US and the UK.
I want them to be as affordable as possible and that becomes a reality when we spread the total cost across the most sales (Like the escutcheon project).

The goal is to keep the price per pair below £30.00 (It pays to read all of the posts...)

Please join in:

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - Early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - Later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43. housam - Early
44.
45.
46.
47.
48.
49.
50.

If you don't know how to join, just reply saying you want to be included and I will add you.
If you want more than one set, add your name multiple times. It makes the math easier later on.
Thank you.

[Miller]

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - Early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - Later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43. housam - Early
44. Miller - Later
45.
46.
47.
48.
49.
50.

[wayne]

Both early and late style caps have now been scanned and are under evaluation of the best way to reproduce them
whilst keeping cost to a minimum. Any options or advice at this point would be greatly appreciated.
We Believe that the later style cap weak point was the plastic S channel that ataches it to the cap

John has proposed using Brass insert nuts and screws to attach them to the Hinges. I believe that this will be alot better than pop rivets... Much less stress on thin plastic parts.

Unfortunatly the origional proposed option of making the back part solid seems to concerns the production engineer as it would have too much shrinkage.

This is the latest design that they have come up with.

New cap.jpg

Unles there are any objections or anyone can see a better way of making them then this is going to be the new design for the new style caps. Inserts will have a 3mm screw which is the largest that will fit with the current hinge unless we agree to make the hinge hole larger.

Early style caps have to be made as per the original design. 2 pieces bonded together. We have explored several options but nothing else would work.

Old cap.jpg

Unfortunatly, the early cap design has pushed the mould to the larger injection mould machine. Normal minium production quantities used for this machine are way out of out need for them.

Due to the unexpected design changes since this started. The company has offered to do a 1 off run of them at an acceptable price. Any future runs may not be worth while.

If anyone wants the 3d Scans that I have recieved I will send them along. (email me).

If anyone can offer any advice of how to improve the design then please let us know.

[GeoffSmith]

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - Early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - Later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43. housam - Early
44. Miller - Later
45. Geoff - Later
46.
47.
48.
49.
50.

[epipete]

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - Early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - Later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43. housam - Early
44. Miller - Later
45. Geoff - Later
46. Epipete - Later
47.
48.
49.
50.

[RayD]

If anyone can offer any advice of how to improve the design then please let us know.

I’m no expert on the subject ... but ...

Considering how they might subsequently fail ... the lugs breaking off for instance ... is it worth asking if the hinge holes could be part of the main component, in a recess, covered by a clip-on cover.

B Post.jpg

Ray

[Brit-Car-Nut]

If anyone can offer any advice of how to improve the design then please let us know.

I’m no expert on the subject ... but ...

Considering how they might subsequently fail ... the lugs breaking off for instance ... is it worth asking if the hinge holes could be part of the main component, in a recess, covered by a clip-on cover.

B Post.jpg

Ray

Unfortunately, the geometry doesn't work with that type of solution and adding a cover adds significantly to the cost as it is another mold part to make.

If the hinge spring was less intense, I would worry less. I am considering asking if they can at least connect the lugs to the rear of the cap which, like a girder, would offer more support during the lifting phase.



Also considering adding a third lug to improve strength:



Wayne is concerned that adding the third hole would be a challenge for some, but if it makes things stronger without adding the silly "S" shaped piece, then should be considered.

[Ladythorpe2]

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - Early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - Later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43. housam - Early
44. Miller - Later
45. Geoff - Later
46. Epipete - Later
47. Ladythorpe2 - Later
48.
49.
50.

You know more than you think you know, just as you know less than you want to know. ... Oscar Wilde
epipeteFanatic Posts: 574Joined: Wed 17.08.2011, 10:03Location: Chippenham

[RayD]

Having looked at mine after posting I can see what you mean John,

If the overall cost of using a cover is higher it rules it out in any case but the geometry could have been overcome with a larger backmark on new hinge holes.

Rather than lugs or a third lug is it worth considering a single solid block running the width of the hinge.

Ray

[Brit-Car-Nut]

Having looked at mine after posting I can see what you mean John,

If the overall cost of using a cover is higher it rules it out in any case but the geometry could have been overcome with a larger backmark on new hinge holes.

Rather than lugs or a third lug is it worth considering a single solid block running the width of the hinge.

Ray

Ray:

That was our original suggestion and request. The engineers said that that was too much plastic and it would cure incorrectly and shrink unevenly. That would leave us with an uneven shelf to attach the hinge.

Connecting the lugs to a longer suport beam that is part of the cap and creating a shelf of sorts for the hinge to rest on seems to be the lesser of the two evils.

[RayD]

Presumably there's a need for all the sections to be the same thickness then.

I had wondered ... probably same as you ... about the block being hollow with the nuts loose in the cavity but I imagine that causes a problem getting it out of the mould.

Ray

[Brit-Car-Nut]

Yes. The only way to include nuts is to use push-in nuts which are installed with heat/frequency into the posts. Creating a box with air inside is not possible without adding another layer of complexity to the mold making process. The laptops I work on all use the nuts in very thin posts and support hinges and such. The posts (hubs) they suggest are fairly meaty by comparison. Hopefully, they cah bond the support bridge to the front edge which creates a lot more strength. Adding an additional post will also spread the load better. Better to have the extra post now and not use it than find out it is needed after the production is finished. It could even be slightly out of line with the other two which adds even more structure. I hope to hear from them tomorrow.

[wayne]

Ray

Thank you for your options. (greatly apreciated).

This was one of the early designs that we were looking at with the hinge attachment being solid but was later rejected by the company due to concerns about shrinkage.

22.jpg

I would prefer as much material under the hinge as possible. Your last pic would be my prefered choice if it was possible.

Johns new idea may be better than the one that was proposed earlier. I will look forward to their reply.

[PAUL30]

2. DeanG - Later3. JohnB - Early4. Dunnlor - Later5. Fredflanagan - Early6. Wayne - Later7. NSR-250 - Later8. Wienlot - Early9. Cliff - Early10. Nicowalker1 - Early11. lotustonybassplayer - Early 12. Jimbo - Early13. Ladythorpe2 - Later14. TrevorB - Later15. Nobby - Later16. Steve M. - Later17. theelanman - Later18. pjw12 - Early19.Tekrace - Later20. rip - Early21. rip - Early22. rip - Early23. andyp - Early24. inkitin - Early25. SteveB - Later26. TTE200 - Early 27. BDC Peter- Later28. DavidEJM - Later29. Debchgo - Later30. Basher - Later31. PerS - Early32. Lotus54 - Later33. MPx - Later34. housam - Early35. housam - Later36. markv - Later37. Gareth - Early38. Carlotus - Later39. Jeemy - Early40. Monty - Later41. Harvey - Early42. Axel-F - Later43. housam - Early44. Miller - Later45. Geoff - Later46. Epipete - Later47. Ladythorpe2 - Later48.Paul30 - later  49. 50.

[Brit-Car-Nut]

1. Brit-Car-Nut - Later
2. DeanG - Later
3. JohnB - Early
4. Dunnlor - Later
5. Fredflanagan - Early
6. Wayne - Later
7. NSR-250 - Later
8. Wienlot - Early
9. Cliff - Early
10. Nicowalker1 - Early
11. lotustonybassplayer - Early
12. Jimbo - Early
13. Ladythorpe2 - Later
14. TrevorB - Later
15. Nobby - Later
16. Steve M. - Later
17. theelanman - Later
18. pjw12 - Early
19.Tekrace - Later
20. rip - Early
21. rip - Early
22. rip - Early
23. andyp - Early
24. inkitin - Early
25. SteveB - Later
26. TTE200 - Early
27. BDC Peter- Later
28. DavidEJM - Later
29. Debchgo - Later
30. Basher - Later
31. PerS - Early
32. Lotus54 - Later
33. MPx - Later
34. housam - Early
35. housam - Later
36. markv - Later
37. Gareth - Early
38. Carlotus - Later
39. Jeemy - Early
40. Monty - Later
41. Harvey - Early
42. Axel-F - Later
43. Miller - Later
44. Geoff - Later
45. Epipete - Later
46. Ladythorpe2 - Later
47. Paul30 - Later
48.
49.
50.
51.
52.
53.
54.
55.