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Home > Faults & Fixes > Broken Radio keypad keys 3D Print

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SimonR

Member Since: 29 Sep 2013
Location: Horsham
Posts: 25

2006 Range Rover Sport TDV6 HSE Java Black

Broken Radio keypad keys 3D Print

This seems to be a common problem with early RRS & D3 where the keys making up the keypad on the radio console break. LR do not supply individual keys - and pretty much the only option is to replace the whole fascia panel.

Click image to enlarge

Several on mine are just held in place with Blu-Tac!

What I've done is to first accurately draw a key cap in Solidworks:

Click image to enlarge

I did consider just 3D Printing a new key whole - but getting the text on the front of each key decent quality was beyond me. Instead, I've designed an insert which slots in to the back of the key.

Click image to enlarge

You have to remove the key then snap off the remaining hinge & plastic prongs. The piece (Right) pushes into the remaining void. There are two plastic barbs on the part. Each original key only has one on either the left or right depending on the key. You simply snap off whichever is not required and replace the key.

My 3D Printer (Ultimaker 2) has nowhere near the resolution required to make a decent job of it. It was good enough to try the idea though - and it works.

I've contracted Shapeways in the US to print me a set in very high resolution:
https://www.shapeways.com/product/2SP7QABH...li=ostatus

If they are good, I'll make the part publicly available on Shapeways so any of you can just order them as required. They have ended up costing about $3 each - which isn't too bad. If any of you want the Solidworks (2014) part files or an STL, PM me and I'll mail them to you.

I'll keep you posted how it goes!

Si

Fri Jun 26 2015 10:17am

foxtrotzulu

Member Since: 04 Sep 2015
Location: West Berkshire
Posts: 152

2010 Range Rover Sport 3.0 TDV6 HSE Buckingham Blue

We have this problem and while tolerable it would be nice to get it sorted. Let me know how you get on.

Thu Jan 07 2016 10:21am

SimonR

Member Since: 29 Sep 2013
Location: Horsham
Posts: 25

It sort of worked. Unfortunately not well enough to be permanent.

I ended up buying a new panel from someone on eBay. It was about £100 - but now having a full set of working buttons, I think it was worth it!

Si

Thu Jan 07 2016 10:31am

foxtrotzulu

Member Since: 04 Sep 2015
Location: West Berkshire
Posts: 152

Pity - Thanks for letting me know.

Thu Jan 07 2016 11:03am

Tim in Scotland

Member Since: 30 May 2005
Location: Driving along in my automobile
Posts: 17476

2013 Range Rover Sport SDV6 HSE Stornoway Grey

Have you tried any of the 4x4 specialist car breakers to see if they are breaking any D3's or early RRS's? 2020 Pangea Green 1st Edition D240 New Defender 110 is here and loving it
2018 Melting Silver Mini Countryman PHEV - soon to be replaced
2015MY Corris Grey SDv6 HSE Dynamic, the best car I have ever owned, totally reliable only a cou0le of rattles in 3 years, now no longer in my care
Also in my garage is a 1996 TDi300 Defender 90 County HT made into a fake CSW

Thu Jan 07 2016 9:18pm

rawley

Member Since: 07 Feb 2016
Location: briz
Posts: 1

2007 Range Rover Sport TDV8 HSE Java Black

Hi simon.
Thanks for the post. Great work. I've got one key broken. More of an aesthetic issue than an operational one.
I would like a copy of the stl file please: if you can send it to me i would be grateful. Sorry i can't pm you (have not reached the worthy hights of empowerment it seems
Cheers
Rawley

Tue Feb 16 2016 11:31pm

SH0X

Member Since: 25 Jan 2016
Location: London
Posts: 82

2005 Range Rover Sport Supercharged Java Black

Excellent work very good to see someone thinking out if the oem box and making something. Top Man

Fri Feb 26 2016 4:04am

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