u/Ardenstar

I am the proud owner of a 2005 Roadster. As some of you might know, finding spare parts is not easy since Smart seems focused on electric SUVs nowadays and has stopped making them. I have stumbled upon some used parts, but Xenoy tends to get brittle after a few years of being exposed to the elements. Also they are quite epansive and I didn't want to spend hundreds of euros to get a part that was already brittle.

I am also the proud owner of a 3D printer, which is how I managed to fix the spare parts issue. I started with a 3D scan of the part. Because it was too big for the printer, I split it into sections and printed them out of ASA. I fused the sections together using a soldering iron, extra filament, steel wool, and steel mesh. Afterward, I sanded it, used some filler, and applied paint to make it smoother and match the color (I am not quite there yet).

The new part fits perfectly. I have had it on the car for a couple of weeks and have had no problems so far.

My AMS wasn't working properly; it was jamming regularly, and I kept hearing grinding noises. I disassembled it, and would you look at that! Fortunately, there is a 3D model for replacement on Makerworld that works perfectly (this one, by the way:https://makerworld.com/en/models/1659680-bearing-cover-for-ams-internal-hub-unit#profileId-1755486).

So, thank you so much to Sander. If your AMS starts making grinding noises, it might be worth it to take it apart.