Rebound adjustment knob for RockShox SID SL Ultimate

The SID SL Ultimate comes with a very simple, very minimal rebound adjuster. It's just a small 2.5mm L key pressed into a plastic clip that holds it on the lower fork nut. It's surprisingly light at only 4.2g, but I was curious if I could do a knob and stay under the weight.

This is the result, and with very careful slicing and a 30mm portion of a 2.5 hex key, yep, it's possible.

Note that RockShox includes the hex key in the fork as it can be removed and used to adjust RockShox rear shock rebound damping, so if you've got that specific setup, this won't be as useful. Also note that if you are confident in your rebound adjustment, leaving the rebound adjuster off saves all of that weight, if you're a really die-hard weight weenie.

Printing instructions

For the weight weenie version you've got to go really aggressive - 0% infill, only 2 shells, and some other settings which I don't remember. For a bit more reasonable (because you want a knob and not the end of an Allen key) I'd suggest 0.2mm layer height, at least 3 shells, and a decent infill like 33% gyroid. Pretty much up to you, though, and remember this is never going to be a terribly strong piece.

Assembly instructions

Find a spare 2.5mm allen key and cut it to 30mm.  Press it in until the shaft is 10.5-11 mm past the top of the adjustment knob. If a little more is sticking out, you're probably okay, as long as the knob snaps into place when you install it, you're good.

I used a bench vise for the pressing function, an arbor press would certainly work as well. Could probably do it with a really big set of pliers (but they'd have to be kinda huge) and as a last resort you could drive it in gently with a hammer.