Disney Monorail Door Replacement for Playset

Print your own replacement doors for the Disney Monorail Playset. I printed my doors are at Cura's "Super Quality" (0.12mm resolution). After printing, the doors need to be warped to fit the monorail car. After cooling, unstick door from the print bed. Don't remove the thin pane of filament from the windows (yet). This skin helps keep the window shape during warping.

The STL will print a door with the hinge on the right. If you need a lefthand hinged door, use your slicer to create a mirror image. (Cura has a Mirror icon on the left side; Prusa: right-click the object, select Mirror)

Place the window on the printer bed and preheat bed to around 60-70C to make the door flexible. I placed a small ramekin over the door to help heat it evenly. After a minute or so, use a curved object like a formica countertop edge or coffee mug to warp the door so it conforms to the contour of the monorail car. After the door cools, test fit on the car. Remove and re-warp if you need to make adjustments. Remove the window pane with a razor blade when the door fits.

Last step is to mix some model paint to match the stripe on your monorail. I discovered my blue line is very close to Cricut "Medium Blue" vinyl I already had on hand. Worked really well.

Print Settings

Printer:  Ender-3 Max Neo

Supports:  No

Resolution: 0.12mm

Infill: Any

Filament: Any PLA White 
 

Notes: 

I recommend using a brim to help with bed adhesion.

Warp the door to match factory door shape

Heat the door on the print bed for a couple minutes, then warp the door to the desired shape with a coffee cup or formica countertop edge. After warping, remove filament "pane" from windows with a razor blade and paint the stripe.

Lightly sand with 220 sandpaper if needed for cosmetic or fitting purposes.