Fence Brake Lever for Miter Saw

A friend of mine contacted me asking if I could print a replacement handle/lever for her Ryobi Miter Saw, after doing some digging I didn't find anything. 

I used Claude to design what I'm sharing, it was my first exercise in doing AI aided design - I was rather impressed in how that went as it made some great suggestions along the way, such as the "Pocket fit coupon". 

You will need to re-use the steel insert from the original handle. I found breaking away the lip at the bottom of the old lever allowed me to separate it from the plastic of the original lever.

Print the "Pocket fit coupon" first using the material you wish to print your replacement handle from (PETG, ABS, ASA - something a bit tougher than PLA is recommended) and see which the steel insert fits in the best for you/your printer (it should be a snug fit). Then print the corresponding lever model. 

Included here are are three, named by corresponding pocket size A,B,C — 16.1, 16.25, and 16.45 mm — otherwise identical (4.7 mm hole, 8.2 mm countersink, 6 lug slots, flat top for upside-down printing). You only need to print the one.

When pressing the steel insert into the final handle I found using something about the size of an old dead AA battery worked well. You want to get it pressed in as far as you can towards the top where the screw hole is.