This is my 2nd make of this particular model. As noted in my first make, this does not fit my Danby AC unit, at least not without modification. The vent attachment is the same size and general shape, but Danby uses a different clip setup and has 4 small guide rails or ridges which stop it from sliding into this model. These clips "attach" to a very thin piece of vinyl (I think). At least they do for a few minutes until the hot exhaust air heats up the vinyl making it soft.
Here is how I adapted this DeLonghi model to work with my Danby unit.
- I used the PLA model from my first make and tried to fit the Danby part into it. I used a permanent marker to mark areas of interference, then used a Dremel tool to remove those areas. I did this until the two parts fit together (mostly).
- I measured the areas I removed with a caliper, then added negative parts (rectangles in this case) in the slicer software so those areas wouldn't be printed.
- I printed a second PLA version and test fit it. It nearly fit but there were a few ridges on the Danby part that prevented it from mating with this model.
- I added more negative parts in the slicer to account for the ridges, and printed a third PLA model. In total I added 4 negative parts for the clips, and 4 smaller ones for the ridges. This time it came out nearly perfect.
- I printed the updated model in ASA (pictured), and it fits like a glove!
It was printed in Bambu Lab ASA with 4 walls and 25% gyroid infill. I printed the "rivet" version, (I know these as brass insert nuts). This was my first time using these in a 3D print (via a soldering iron), and wow do they work well!
I used a piece of 1"x6" cedar and cut the opening with a hole saw and jigsaw (a 2.5" hole saw was the perfect size). As my print was slightly warped and boards like this are almost never completely flat, I added some weather stripping.
The most suitable screws I had were #8 1.25" screws meant for plywood (so they have a very broad flat head). These were still a little too long, so once in place I removed the tips with an angle grinder so they wouldn't destroy my screen.
While this was a fair amount of work, I'm very happy with the result. Thank you again for designing and posting the model!
