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Doors and Corners, Kid. That’s where they get you. (Miller)

Something about doors at least. I’m not trying to be completely OCD (or am I) about this loom cutting business – just to save a few grammes. However – having first removed the door cards and realized how much wire, and how thick, was in there, just cutting off the not needed part was never going to – ehhrm, cut it. So after having finally managed to remove the connecting rubber thingy and it’s mounts (which is another exercise in swearing) the solution was pretty simple. Keep the stock rubber thingy. Remove the clip from the door side and the multipin connector from the body side and replace them with simple squishy things.

Standard body to door connector thingy full of yucky stuff.

with all the wiring that goes into the door. Speaker cable has already been removed here so this is technically not everything that’s going away.

So – an hour and a half or something in Fusion360 and out of the printer comes these:

They will be printed in some carbon fiber induced PETG before final assembly.

And mounted with a 5 core 1mm2 multicable – figured the outer sheath would hurt since there will be some movement.

So much easier on the eyes than the standard part – should drop a few grammes as well.*

*Couldn’t let that stand, so here’s everything removed from the passenger side door (minus speaker cable) including the motor for the central locking system.

555 grammes (it was zeroed out with the cardboard) – so realistically, including a short piece of the 5 core cable, we’re looking at a saving of at least 800 grammes. JUST wiring for the doors. (as said, I try to not be too OCD about this weight saving program)