Volvo Key Bow Replacement

Edit: Added v2 w/ a tight press fit for the transponder.

What we're replacing (Although you wouldn't be here if your key was in this good of a shape).

The OEM keys are made with a rubber over-molding that degrades with time. Eww…

This replacement design fits the key blade and has a 3.5mm x 3.5mm x 14 mm void to house the transponder for the key bow. Since this requires destroying your original key bow, please make sure that your vehicle's key matches up correctly. I have pictures attached that may help provide context for various points of the process.

Prep-

I pried away the bulk of the over-molding that remained with a simple screwdriver (Requisite: screwdrivers are not prying devices…) until the majority of the plastic key bow was exposed. Then I slowly whittled away the plastic with a utility knife and cutting pliers. Take care when doing this as the transponder in this model uses a glass shell, which you definitely don't want to be breaking. Slow and steady wins the race here. Then I used isopropyl alcohol to clean up the key blade.

Printing-

Just as with the upstream design, you need to insert a pause when slicing - just before the pockets are to be enclosed. I also painted on seams, but you definitely don't have to.

When inserting the transponder - I don't know if its orientation matters (I should have taken note when getting it out of the original key…), but it should drop in easily. Since this is not a press fit, the transponder will rattle within the completed key. (It's not a bug, it's a feature! >.> ) If this bothers you, either shim it/place a dot of glue in the bottom of the void during the pause stage or I can prep a differently sized void (I have a second key that I'll be processing, so I may try that out).

When inserting the key blade - the fit is quite snug, but this is a good thing. Just make sure that you're only applying downward pressure and not shifting your bed in the process.

Resume print, post-process, enjoy!

Key info-

Volvo part number this is modifying: 9203132