Improved parts for Lunar Lighthouse Puzzle Box

This is an suite of behind-the-scenes upgrades to 3D Printy's Lunar Lighthouse Puzzle Box (the already improved version, so we have a good starting point). I really love 3D Printy's puzzle boxes, especially the way he uses magnets to give a clicky/springy feedback to the user.

Update: I have another remix of just the lamp room and cap made for a vial of tritium, for self-illumination—https://www.printables.com/model/990325-tritium-vial-lamp-room-for-lunar-lighthouse-puzzle.

Design features

I've found that two surfaces with magnets sliding across each other generates a risk of something getting caught or glue working itself loose (especially if not fully cured). To address this, I've modified several parts to insert the magnets differently, or to embed them while printing.

I've also noticed that using a bolt through plastic to attach parts can weaken over time when those parts are manipulated a lot. To solve this, I redesigned the bottom shell to have 3 nuts so that the connection to the base is incredibly strong.

Where possible, I've tried to use multiples of 0.6 for internal z-axis allowances. This should help keep the spacing the same across a range of layer heights you may print with.

Most of my modifications are fully interchangeable with 3D Printy's improved version—you can take any or all of them. I didn't include any non-changed parts, so you'll need to download those from the original model.

Hardware changes

• Replace 3 of the M3x12 socket head bolts with anything between M3x16 and M3x20.
• Add 3 M3 DIN 562 square thin nuts (yes, this is a different nut than used for the nutty moon disk… but I promise you'll like these).
• Add a 3x3mm and 1x1mm cylindrical magnet for the moon upgrade.

Walkthrough of changed pieces

Toggle Buttons

• The single magnet on the toggle buttons is now inserted from the side, not the bottom.
• If it's loose, add a drop of superglue in after you set the magnet (from the side entry point). I found it helpful to turn the piece on its side (entry point up) and letting it dry in that orientation.

Slider

• The magnet is embedded into the print.
• The piece now has the word “TOP” with up arrows debossed onto each curved side a visual aid.
• During the printing pause for magnet insertion, I usually add a small drop of superglue into the part and then place the magnet in. It will work fine without the glue, but that prevents rattling.

Bottom Shell

• There is a small rectangular opening near each bolt hole, to accommodate a M3 DIN 562 square thin nut.
• Slide the nut in gently. If it's loose, you can add a drop of glue, but as long as they stay in place long enough to screw the base on, they will be held captive and can't move.
• The three bolt holes are also widened (so the screw doesn't need to tap a thread).
• Use three M3 socket head bolts from 16-20mm long. (Not 12mm as in the original.)
• I recommend using 5 magnets (the default 3, plus 2 on either side of the rear alignment pin).

Top Shell

• There is a new cylindrical hole for a magnet behind the upper window, to firmly hold the upgraded bonus moon in place.

Moon Disk

• The magnets are embedded into the print.
• During the printing pause for magnet insertion, I usually add a small drop of superglue into the part and then place the magnet in. It will work fine without the glue, but that prevents rattling.

Lamp Room and Lamp Room Cap

• I threaded the connection between the cap and the lamp room.
• These parts are not interchangeable with the originals (you can't use the original cap on the new lamp room).
• I have another remix of just the lamp room and cap made for a vial of tritium, for self-illumination: https://www.printables.com/model/990325-tritium-vial-lamp-room-for-lunar-lighthouse-puzzle

Bonus Moon

• A tiny 1x1mm magnet is embedded into the print.
• This moon is fully compatible with the original, but if you use the upgraded top shell with a magnet behind the window it will be held in place more securely.

Printing and assembly tips

• Print the pieces as oriented in the .stl files.
• Pay particular attention to slicing and printing parts with embedded magnets. If you are using my .gcode, the parts with embedded magnets have a custom pause routine that slowly extrudes for a few seconds and then slowly moves the extruder to help get rid of excess oozing.
• Make sure glue is fully dry before assembling pieces (I let the gel superglue sit for a full day usually).
• I like to figure out the polarity of my magnets and by convention set them so that N is upwards and outwards from a model, and S is downwards and inwards towards the model. This helps ensure sub-assemblies are compatible from make to make.

Safety notes

• Supervise your children at all times.
• The upgraded bonus moon, lamp room, and lamp room cap are choking hazards for children under 3 years old.
• Magnets and superglue are dangerous for kids (and adults too).

Thank you to 3D Printy for an amazing model!