ITT Thermostat Cover

We have an old ITT thermostat in our apartment (model number T99BV305J). The cover is broken (one of the hinges snapped off) and is discontinued by the manufacturer. Instead of buying a replacement part (for around $40), I designed a 3D-printable one. 

My version has a swappable top cover plate which is held in place by 6x2mm magnets (because magnets are cool). You can design your own cover plates to match seasons, holidays or special events.

Parts to print (and how to print of each):

• Cover (x1)
• Hinge (x2)
• Catch (x2)
• Magnet Clip (x4)
• Cover Top Plate (x1)

Additional items:

• Small cylindrical magnet 6x2mm (x8)
• Cyanoacrylate glue (to attach magnets, hingers and catches)

Printing Cover Tops:

Cover tops sit on top of the cover and are held in place with four magnet clips. Cover tops are 2mm thick, with a 1mm base layer and a second 1mm layer that has a border and temperature numbers. I would suggest printing cover tops with 2 contrasting colors. Mine have a dark base layer and a bright top layer. 

I've provided 3 different cover tops. One just has numbers – this can be used as the base for your own tops. The other two are an image of my dog Kona's head, and a festive day of the dead image.

Assembly:

• Dry fit hinges within the cover slots before applying glue. Place them with the flat side facing out, toward the cover sides. Make sure they fully seated within their slots.
  • NOTE: These have tight tolerances by design. They fit, but it's tricky to move them into place. This was done to ensure the cover fits exactly and doesn't sag. Dry fitting is a good first step to make sure you can glue them in place successfully. 
• Remove hinges, apply CA glue, and replace the hinges.
• Dry fit the catches before gluing them. Place them with the raised tab facing toward the inside of the cover.
• Glue catches in place with CA glue.