Switch overlay for Dewalt DXF1616 Fan
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Turned the recessed switch on a DXF1616 fan to a raised switch
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This is an overlay that allows the switch to be a paddle or other handle to control the switch.
The frame mount is removable. It uses expanding TPU feet to hold it in the current screw holes without touching the existing screws.
I designed it for where I have my fan stored.
Materials Required (if you don't use the developer pieces to change sizes)
(4) 6/32 bolts and nuts
(1) 5mm thread insert
(1) 5mm bolt
Assembly:
Melt the 5mm Thread insert into the spindle
Place the spindle over the original switch
Put the 4mm bolts through the frame holes on each of the 4 corners
Add the TPU grips and thread them without compressing.
Insert the TPU grips into the fan screw holes after guiding the frame over the spindle and push until the frame is flush.
Tighten the screws until the frame is snug and does not want to pull out. Do NOT over tighten. They just need holding power.
Place the handle over the spindle and install the handle.
Install the 5mm handle bolt. Do not over tighten. There is no twist pressure on the bolt. It just needs to hold the handle on the taper.
Material. Your choice. I used PETG.
DEVELOPER PARTS
If M5 insert is inconvenient to you, there is a solid spindle included for you to cut your own hole.
If 3/16 bolts and nuts are inconvenient, the TPU parts are available for you to cut your own hole. Be aware there is solid only on one side to cut in the nut. The other end is thinner and for the crush-zone.
If you want to design your own handle, there is a developer blank with the tapered connector you can mount a handle of your own design to.