I managed to break part of the clip off my filler flap which now doesn't snap shut properly.
Luckily I have access to a 3D printer and one of my colleagues has a home made forge so I plan to design and make a replacement for the broken part out of plastic, then create a mould and cast it from aluminium.



Here is the design for the repair part, it will go behind the 'stump' shown above



More pics once I've printed the part

Oooh exiting, do share the pics! Good luck!

Possibly a bit over the top but if it's an engineering challenge then go ahead, the greatest issue I see is attaching it to the existing flap as far as I can see it's made from polymide which is very hard to glue to if at all have you considered a secondhand one ? and spray it the correct colour.

It gets bonded to the existing part and fits inside the old recess, so a bit of Sikaflex should do the trick.

Was just going to bond it from the back as the stress will be in another plane...

Spray a secondhand flap... My car is a 3 coat cordello red, not a chance of a match!

Over the top? Possibly, but in character for me... My ofirst thought was to make a servo operated remote control one...

....have you not seen the rest of my mods?!

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