When I removed the shift lever from the gearbox of my Daihatsu, the rubber that held it in place crumbled in my hands. I spent the next 10 minutes fishing out all the remnants from the mounting position.
Luckily I managed to save this chunk of material, giving me a good starting point for reverse engineering.
I started by spraying it with chalk, as 3D scanners tend to have a hard time scanning dark objects. Afterwards, I put it on a turntable and made a 3D scan of it using my Revopoint Pop 2 scanner.
With this 3D scan I was able to reconstruct an accurate model in FreeCAD. As this part won’t see any heavy loads I figured it was okay to just print it directly out of TPU as opposed to making a mold of it and casting it out of 2 part urethane.
The result was an accurate reproduction of the original rubber, fitting perfectly in the original location around the shift lever.
