Anyone Have a Solution for The Door Hinge Padding

[F500guy]

I have 1600 miles on my build, hope to get in for paint after summer driving season. Focus this summer will be the nagging details to polish off the interior details.

I was thinking of getting some leather bits stitched, maybe with snaps or Velcro and add some closed cell foam and wrap the hinges, each upper and lower bar separately. Just wondering if there has been any other solutions folks have thought of for these pesky metal parts at the knee.

[rich grsc]

I wish someone could 3D print some covers for these. These hinges are dangerous if you have an accident. I ended up with 8 stitches just below the knee, cut to the bone.
I tried to bring this up with Dave at Sema, but our conversation got interrupted and didn't get to finish.

[TrackDay17]

Maybe a fabric like suede or a small piece of Alcantara with velcro would be more flexible than leather ?
Maybe you could stitch some small foam padding to it also to soften any knee encounters ?

Another thought I just had was possibly a 3D printed cover out of a soft plastic or rubber of some kind that could be slipped on and glued to the hinge piece ?

Just thinking out loud as my car is far from being finished.

I guess I should've read Rich's post about 3D printing before I posted !

[Kivyee]

I wish someone could 3D print some covers for these. These hinges are dangerous if you have an accident. I ended up with 8 stitches just below the knee, cut to the bone.
I tried to bring this up with Dave at Sema, but our conversation got interrupted and didn't get to finish.

Yeah a TPU print can easily deal with the required shock absorption and still look pretty slick - If someone else doesn't tackle it I'll give it a go once my CAD skills gets up to speed.

[rich grsc]

It's just that the arms are square cut metal and sharp.:mad: Something to soften the edge would help

[bobl]

I cut a piece of aluminum and riveted it on to cover the hinge sharp edge. Then covered it with carpet so you don't really see it. It's got enough give to provide some flexibility. In my case my knee digs in right at that hinge.

[Stangrob]

So, I'm still building my car as well, so I don't have a solid idea of where the problem is. I suspect it's the upper and lower hinge points that allow the hinge to wrap around the body. Please look at my photo and let me know if the arrows are pointing to the offending parts:

226632

If so, I can probably design something to cover that. My new printer works with TPU, and it'll give me an excuse to play ;)

Thanks!

Rob

[F500guy]

That's it...

[rich grsc]

Thats it exactly

[StangRacer]

So, I'm still building my car as well, so I don't have a solid idea of where the problem is. I suspect it's the upper and lower hinge points that allow the hinge to wrap around the body. Please look at my photo and let me know if the arrows are pointing to the offending parts:

226632

If so, I can probably design something to cover that. My new printer works with TPU, and it'll give me an excuse to play ;)

Thanks!

Rob

Can you do something like the covers on the original cars?

226635

[Andrew Davis]

Have to admit, my solution was rather crude. i used an appropriate length of rubber 3/8 fuel line, split down the middle and zip tied at the ends. Am sure it's not IHRA approved, but saved some left knee discomfort.

[F500guy]

Have to admit, my solution was rather crude. i used an appropriate length of rubber 3/8 fuel line, split down the middle and zip tied at the ends. Am sure it's not IHRA approved, but saved some left knee discomfort.

That was one of my options, maybe wrap it in leather so the hose print is not visible...

[Stangrob]

Can you do something like the covers on the original cars?

226635

I've seen those and was originally thinking the same. While I think it's doable, you currently can't get that kind of finish with a 3D printed part (I'm pretty sure the current ones are all injection molded). You'd probably need to cover the print with something like leather or vinyl, and that would be a bit of a pain. Let me first try covers for the top and bottom parts of the hinge and go from there.

Rob

[JJK]

3D printed parts can be sanded and painted to look smooth without the layers showing, especially if you use paint filler first.

[Stangrob]

3D printed parts can be sanded and painted to look smooth without the layers showing, especially if you use paint filler first.

Yes, I totally agree with you. That would be another option for filaments like ABS and PETG. I'd be curious though to first try the TPU. A little cushioning can't hurt ;)

Rob

[CABulldog]

I like this idea I have PLA+ and PETG, I would just use some foam and leather to cover it rather then try and paint it. I used https://www.amazon.com/dp/B08RB26KN6?ref_=ppx_hzsearch_conn_dt_b_fed_asin_ti tle_4&th=1 for my dash and a thicker one for my transmission cover. Rob I would be interested in the files once you have something that works well.

[mrglaeser]

This may be a dumb idea. But what about gluing some water resistant batting to the 2 crossbars and then wrapping it with leather grip tape for bats and rackets? Should provide decent padding and it would look like something a driver in the 60s would do.

Something like this:
https://www.amazon.com/TOURNA-TLG-T-Leather-Grip/dp/B00STUOJCS/ref=sr_1_6?adgrpid=189090158849&dib=eyJ2IjoiMSJ9.X0IY1tYkHFrRfw68llRe5SMrIKDxd_tzM UevWBY8xn5l0PgjxteMq0K8b407tBFjxMDZN71T_g8pqpgTa_7 3XQJ5wBoGUUVnDHnKBE5SyzLOmsWFEMtNC0WlPe9IQBVJF152q Ip7q3AqySSPzgUiVmCXi9Y0ZvWMBApBI8Iiz88oWuf1ERA6IEV xq-4-k6JeKf-kvfXLA-In6PWf0MldIRuJRPXgnAA5TdQWLqTUWqlCwTHvjHlzJ3-zhubv5aJeit52tHPlRGb9wU8wEdAnh5ugmqboK-qrd3ZnQM43Whc.LUoBJcRDS82YKQFbdLc3FYtTwaeToekddBmg 6OqWNpE&dib_tag=se&hvadid=779585555736&hvdev=c&hvexpln=0&hvlocphy=9019698&hvnetw=g&hvocijid=14404621023972672671--&hvqmt=e&hvrand=14404621023972672671&hvtargid=kwd-300752333171&hydadcr=16063_13515911_2125738&keywords=leather%2Bbat%2Bgrip%2Btape&mcid=9f6db03d83253ffa9dbb598eca859380&qid=1773331041&sr=8-6&th=1

I have a tan interior but there is black tape out there too.

[rich grsc]

That would be better than how it is now. :) When mine is at paint, I'm going to sand over the sharp edges, then see how slipping some hose over it looks and maybe this tape to see which I like better. Just rounding over the edge is better than nothing, so everyone, just consider at least that. You really don't want your leg laid open to the bone, with a bunch of stitches. It would get deleted, or I'd post a picture of what happens when steel hits flesh

[cdurbin328]

I'm a mechanical engineer (30+ years) and 3D print all kinds of car stuff.
I'm thinking I might have to give this one a go.
Stay tuned.