Custom Sleeves for TPU Shock Absorber Bushings

This time, making custom sleeves for 3D printed TPU shock absorber bushings for a Mazda B2600 4WD pickup.
Had to make 2 changes to the bushings. First was to make some sleeves for the lower shock mounts, front and rear. Both these mounts have a pair of tabs with a plain bolt through the center. The sleeves are needed to stop from over compressing the bushings and deforming the mounting tabs.
Secondly, we needed to tighten up the bushings in the shock eyes. I added a CAD file parameter, ODextra, to add (or subtract) a small amount from the bushing OD for a tighter or looser fit. Originally, I had hard coded this into the bushing dimensions, but it got very confusing to keep changing those dimensions. Now, the original bushing outer diameters remain fixed and you simply adjust this one parameter to alter the bushing diameter. There's a similar parameter for the bushing ID clearance as well.
Rancho shocks used:
Front: RS980:
- Lower straight bushing: 40mm wide, 16mm ID w/ 16x12 sleeve
Rear: RS999202:
- Lower L3 hourglass 40mm wide, 16mm ID w/ 16x12 sleeve
- Upper L3 hourglass, 39mm+4mm spacer or 43mm wide w/ 4mm offset, 20mm ID
Needed a total of 4 sleeves, 40mm long, 16mm OD x 12mm ID
Use a seamless tubing for custom sleeves:
amzn.to/3I5FhpW
www.mcmaster.c...
I used the Zyltech TPU filament:
www.zyltech.co...
Shore hardness: 95A
3D Printer Files:
Original:
- www.thingivers...
New:
- www.thingivers...
- cults3d.com/en...
- www.printables...
I also added the B2600 specific SCAD variable lines in the Thingiverse page, not too hard to figure out.
If you make some of these bushings, post a comment here or on the Thingiverse or Cults3D site what filament you used and how they worked for you.
More to come...
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[@The4Crawler]

This project really helped to dial in the 3D CAD model file with all the user parameters. My original model was hard coded with dimensions and that made it very hard to make changes. Couple that with using radius instead of diameter for dimensions. The new model file has all the parameters separated with separate inside and outside clearance settings.
This makes it so easy to measure the needed width and hole size and then print out TPU bushings of that exact size. Basically make the bushings fit the vehicle and sleeve material, if needed.