READ DESCRIPTION 1/2 Scale Federal Signal Thunderbolt

FROM MY END, SUPPORT FOR THIS HAS ENDED. THIS IS VERY BAD IN MANY WAYS, AND I HAVE CANCELLED SUPPORT AND MOVED ONTO REMODELING ENTIRELY. YOU CAN ATTEMPT THIS, BUT YOU WILL DEFINATELY HAVE TO MODIFY MANY THINGS YOURSELF.

I am only keeping this up for people who are in progress, so they can finish their build if they want to. 

If you are new here, don't bother printing. IF you want a thunderbolt, check out my friends models:

HaroldHiHat, his 1/3 scale thunderbolt will be released soon

Scott's 1/4 scale, absolutely insane performance for such a tiny model :

That aside, here is your instructions if you desire to finish your build.

Recommended minimum 225x225x225, CC or similar core XY printe.r. 1003 requires minimum 250 Z height due to taller rotator tube.

Horn will need further splitting if you have a printer smaller than 256x256x256.

Full tutorial video will come once I finish mine.

Because of occasional printer goofs, some holes may need to be slightly drilled out to size.

---PARTS LIST------

General Hardware:

Slip ring material: https://www.amazon.com/ANGKEEL-Conductive-Grounding-Shielding-Decoration/dp/B097HGGSLQ?crid=2NRHW0FGHMK6G&dib=eyJ2IjoiMSJ9.twcaKH8dqv5khF3SmFdkb7MhM8k3ZCx3SCb8GWzMTcxMOgXUqetVgWinJraObnzQp3h_YnAG0jbD-0bMeR6YESx462w6szZk_M_cP3jMN2qQpPb6nQTV2drehN1sQxmDJBo6WoA5MEcCrBNqrrdDkn5gW9xalvUMl48WZa-mfAZdycBZlSws8INrWUZ8hrigoL4ZRGpzIH_ECQUeFrZyJfPQ5NFrDu3oPFOuxd5jncPWqCcO0lPQC14b_5PSki_Yds4AINjI3byc4dqy6gssDF2kjQ6mkgfDaWVf8Cpw5xQ.2Qz9KNgm3pQpe4KADibnFKpQduzq3fulWF2GpD9QYPo&dib_tag=se&keywords=copper%2Bstrip&qid=1770234919&s=hi&sprefix=copper%2Bstrip%2Ctools%2C141&sr=1-6&th=1

M2 Inserts: https://www.amazon.com/ruthex-Threaded-Insert-pieces-ultrasound/dp/B088QJG676?crid=U547FY217274&dib=eyJ2IjoiMSJ9.Kklsn2ALETWMyH1Of0tnBLIToPbIyk5aRwYXO_KdUlNyBinWPIQ8xmeqk9JcHJBMln8PTVJiqjSCZlYA11WKoVe1Pd-EBEYWzKGfqkxoycDsTqmIstohbD7zSkyYwq0RDh5ng5yvU7HfGG4coPAisBJ1t1US7qSBdPAk5MP3bbSdwYmQlJRCZZL2fdURxrSZZRB6vjbimxpX4imH52rqLclGzuG9HRuYdhJp5MnuLV8._sZdwdHbl_6b_k15LW4EuN1wjLAd19qo5YcltWHxssw&dib_tag=se&keywords=m2+inserts&qid=1770238020&sprefix=m2+inserts%2Caps%2C132&sr=8-4

M3 Inserts: https://www.amazon.com/ruthex-M3-Threaded-Inserts-RX-M3x5-7/dp/B08BCRZZS3?crid=PHXFLVY6VE1Y&dib=eyJ2IjoiMSJ9.hCLo9gXrDlmfVXJtYGyEKO3aeE_xp54VlEE6oKrjqiowFM8zCZh-7ZxBTdBMOgSV87BQrYqyl11DqFyViIes78deKG3qY-e1YqPMGyX7S0BkzHXIkSAk4n29kMD2dbTE-5FNv3L_eav-fxvb07TeA21EgZazp8_CFwlCZiBT_q6njcy_jmgDBlHreG2b1u40N3-e-u6imdlrLBR9Bfm1JVeDndEhhfwvm_qxnE_f4BM.SL4ZCVB9f7fkIaWNvZPph7CPlc3mV0eMFLQjwpHOxqM&dib_tag=se&keywords=m3+threaded+insert+set&qid=1770237970&sprefix=m3+threa%2Caps%2C105&sr=8-5

M4 Inserts: https://www.amazon.com/ruthex-M3-Threaded-Inserts-RX-M3x5-7/dp/B07YSV66Y5?crid=PHXFLVY6VE1Y&dib=eyJ2IjoiMSJ9.hCLo9gXrDlmfVXJtYGyEKO3aeE_xp54VlEE6oKrjqiowFM8zCZh-7ZxBTdBMOgSV87BQrYqyl11DqFyViIes78deKG3qY-e1YqPMGyX7S0BkzHXIkSAk4n29kMD2dbTE-5FNv3L_eav-fxvb07TeA21EgZazp8_CFwlCZiBT_q6njcy_jmgDBlHreG2b1u40N3-e-u6imdlrLBR9Bfm1JVeDndEhhfwvm_qxnE_f4BM.SL4ZCVB9f7fkIaWNvZPph7CPlc3mV0eMFLQjwpHOxqM&dib_tag=se&keywords=m3%2Bthreaded%2Binsert%2Bset&qid=1770237970&sprefix=m3%2Bthrea%2Caps%2C105&sr=8-5&th=1
(you can probably find a really cheap kit that has m1-m5 inserts for like 10 bucks, but its best to get separate to stock up for other future projects!)

Screw Set: https://www.amazon.com/Kadrick-Assortment-M2-M3-M4/dp/B0CQJZCC9T?crid=3NICM4JM3YPFH&dib=eyJ2IjoiMSJ9.ncyV8tPUVstuZ5sBJdqTmupy42Br1vHi-0LUvgCFFbmG8bcf9mG5CWJC8ykxWhYnEWbngI-VcgGqj0-JNJtFdynddaLBULv0HyPHdbb2dVIiH9rT9Zb0mUVaKJG4kYcmwGzOlYktG9jUZLyPl3EgmMDC03i1c3RKZw7IPk2LXtQZvquNs23M40J96jPaCU6kwBZyF2DOyfTQuusVrDAGeTpc_JJbRnWfiUe_Y-3L-pM.yWcnZ0hfSB9TnuZgbdAdU0bS79xJ__HUJV0jTunetko&dib_tag=se&keywords=m2%2Bm3%2Bm4%2Bm5%2Bscrew%2Bassortment&qid=1770238059&sprefix=m2%2Bm3%2Bm4%2Bm5%2Bs%2Caps%2C141&sr=8-3&th=1

Extra: If you want the horn to be installed with the accurate hex screw head, use these: https://www.amazon.com/Fgruh-Assortment-Washers-Assorted-Printer/dp/B0FGV8F6G7?crid=ETLAHBX6FJ74&dib=eyJ2IjoiMSJ9.0dXLj7wldO0GxvpiCSdpLCd0RvqoI15u77QqkO_QaphELjco-TDIIdLckfMwObAzN1p0jI1FjHIqhD5udQF0S9qLpHJPtnLIyU2CxfsDrLG2ZeTyqaic0LEEihjCov1M2zxj4Epz4ETlpo1PPJPwoaOAQZqR4VlVQBIoLxRx2JjjlOr844EFHcJUpO8sgxSUqSd5j5puGBchQIZNDBzLdbUp-2X5_BkHY53cN5Ts_0g.3R57xQbcvWSyPKOEBrtYNtmGEyN478j_me8Ph-aDrKE&dib_tag=se&keywords=m4+hex+screw&qid=1770238107&sprefix=m4+hex+scre%2Caps%2C147&sr=8-3

CORE:

775 DC MOTOR:

any should work, but I use this on: 

https://www.amazon.com/Electric-Extension-Cylindrical-Cutting-Machine/dp/B08DG2KXZB?crid=2XF4U93PNBTH5&dib=eyJ2IjoiMSJ9.bSjlGeTgixfV_K93zcgyGk3aGVMLgedhDdjQMW_jCNmnekf_FJvRqdVFbt__N6ZKHPS4yGyp3ZEDrVybaUNtPBTyHMu_mHtHBNmY2qt0qN8p7alYLRz8-JzQzm2SXQysk9vY8kMWgJJ6-5AfAtpZpQlOd4neILYoVQt4rTdmeyiH4b2KN0THrwiihUTkTBmZFLlmmNv__xBtAkcJUr0pcS47WA-VkaSNvswxPOgSNC06HkhbK0VIMErEnUSYqBL8mWesZG0x_5bwD2dHfjqul9V51SQ0Z7oPgZYS47UsOZ0.GygOCjxksz7QP3noiBIaefw1yGXbGidqrTjy3ePIVtM&dib_tag=se&keywords=775+dc+motor&qid=1770328277&sprefix=775+dc+moto%2Caps%2C144&sr=8-32

A sort of sealant like gasket paper or some form of RTV can help enhance the seal of the cap, helping prevent air leaks  (more air = louder)

Rotator (both A and B, 1003)

Rotator motor: https://www.amazon.com/dp/B07F8Y36PD?_encoding=UTF8&psc=1
Anything similar at 12 RPM should work.

Rotator motor clutch coupler: https://www.amazon.com/Coupling-Connector-Coupler-Accessory-Fittings/dp/B08335MYGW/143-3993027-6914543?pd_rd_w=kcuc9&content-id=amzn1.sym.de9a1315-b9df-4c24-863c-7afcb2e4cc0a&pf_rd_p=de9a1315-b9df-4c24-863c-7afcb2e4cc0a&pf_rd_r=03DF8HAH204DFGE6HK19&pd_rd_wg=rUTJS&pd_rd_r=ad5c542f-3020-420b-9e32-3488bfb851d1&pd_rd_i=B08335MYGW&th=1

INSTRUCTIONS(incomplete)------------------------

Start by printing your rotor of choice, corresponding chopper cap, and the motor holder. Print the rotor at 100 percent infil. Cap at minimum of 75 because its supporting the weight of the horn.

Remove the metal sleeve thingy from the 775, and put the motor into the holder. Hold it in with 2 m4 screws. Press your rotor onto the motor shaft. If it is too tight, modify the rotor in tinkercad or similar software. If you need to adjust it to be more than .3mm larger, your printer has serious issues and you may not want to proceed on this project. (trust me, i've been there, save yourself the suffering.) 

Install your chopper cap with m3 screws, making sure to equally tighten them. If desired, put a bead of RTV Sealant around the caps contact area to create an extra seal.

Hook your motor up to some wire, preferably a few feet of wire so you can easily hook to the slip ring. Connect to a power supply and run the core. If it works, beautiful, proceed. If not, remove the cap and sand the inside of the cap with sandpaper, i usually use 60 grit because its fast and effective. Repeat until scraping stops.