My Daughter's Phil and Teds E3 Pushchair has a plastic moulding which
holds the sprung brake lever.

This moulding has broken and the brake no longer works. The moulding
is a brittle plastic which I think this is a poor design for an
important safety item.

The moulding is not available as a spare.

Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)

The push chair is out of warranty by the way before the lawyers step
in.

On Mon, 23 May 2011 03:33:12 -0700 (PDT), chudford
wrote:

My Daughter's Phil and Teds E3 Pushchair has a plastic moulding which
holds the sprung brake lever.

This moulding has broken and the brake no longer works. The moulding
is a brittle plastic which I think this is a poor design for an
important safety item.

The moulding is not available as a spare.

Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)

I would be tempted to use a bit of metal - mild steel for example.

--
Frank Erskine

On May 23, 2:59*pm, Frank Erskine
wrote:
On Mon, 23 May 2011 03:33:12 -0700 (PDT), chudford

wrote:
My Daughter's Phil and Teds E3 Pushchair has a plastic moulding which
holds the sprung brake lever.

This moulding has broken and the brake no longer works. The moulding
is a brittle plastic which I think this is a poor design for an
important safety item.

The moulding is not available as a spare.

Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)

I would be tempted to use a bit of metal - mild steel for example.

--
Frank Erskine

That would be ideal but would require an NC machine as the mould is a
complicated L shape with two holes for tubing as well as a slot for
the brake.

Frank Erskine wrote:
On Mon, 23 May 2011 03:33:12 -0700 (PDT), chudford
wrote:

My Daughter's Phil and Teds E3 Pushchair has a plastic moulding which
holds the sprung brake lever.

This moulding has broken and the brake no longer works. The moulding
is a brittle plastic which I think this is a poor design for an
important safety item.

The moulding is not available as a spare.

Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)

I would be tempted to use a bit of metal - mild steel for example.


Indeed. Or brass if yuo cann get it.

Its surprising what a few hours of elbow grease and files can do by way
of turning a solid lump of metal into a usable component.

Another option is cold casting resins and suitable fillers.

chudford wrote:
On May 23, 2:59 pm, Frank Erskine
wrote:
On Mon, 23 May 2011 03:33:12 -0700 (PDT), chudford

wrote:
My Daughter's Phil and Teds E3 Pushchair has a plastic moulding which
holds the sprung brake lever.
This moulding has broken and the brake no longer works. The moulding
is a brittle plastic which I think this is a poor design for an
important safety item.
The moulding is not available as a spare.
Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)
I would be tempted to use a bit of metal - mild steel for example.

--
Frank Erskine

That would be ideal but would require an NC machine

A human with a file makes a very good NC machine..


as the mould is a
complicated L shape with two holes for tubing as well as a slot for
the brake.

Sounds dead simple to me.

On Mon, 23 May 2011 03:33:12 -0700 (PDT), chudford
wrote:


Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)

Use polymorph.

http://www.remap-internet.org.uk/rem...ic+-+Polymorph

On May 23, 4:51*pm, Peter Parry wrote:
On Mon, 23 May 2011 03:33:12 -0700 (PDT), chudford

wrote:
Have the team any ideas for a replacement, perhaps making a new
moulding (how would I do this?)

Use polymorph. *

http://www.remap-internet.org.uk/rem...hp?page=Low+Te....

Thanks Peter
That sounds ideal.
Has anyone used it in a medium strength application?

On Mon, 23 May 2011 09:12:18 -0700 (PDT), chudford
wrote:

That sounds ideal.
Has anyone used it in a medium strength application?

At up to 50 deg C it is similar to nylon and very tough, it won't
crack. Drilling it requires care as the heat from the drill bit melts
it - drilling under water is best. Above 100deg C it becomes adhesive
and will stick to you (and burn you).

On May 23, 5:12*pm, chudford wrote:

That [Polymorph] sounds ideal.
Has anyone used it in a medium strength application?

Yes - worked fine.

As Peter says, it's hard to saw or drill as it melts at such a low
temperature. Hand tools and working slowly does the trick.