Volvo Cover Washer and Gasket (8250235, 30751307, 9207806)

When converting a vehicle from Manual to Automatic or to Electric, the clutch master cylinder is not used anymore, leaving a hole in the firewall. Automatic cars came with a cover washer in place of the master cylinder, but it appears to be no longer available from Volvo. So if you don't want to dig through scrapyards to find one (or not), you can make your own with the provided models.

I do not recommend to 3D print the cover washer, because one bolt is shared with the pedal assembly. If you do, use a strong plastic. Otherwise I would recommend using the provided DXF file to make one from metal (or 3D print a template).

Furthermore you can find the model files to 3D print a gasket or use the print as a template to cut it from the gasket material of your choice.

Versions

Cover Washer - This is the plate that replaces the clutch master cylinder. A dxf file is provided for laser/water/plasma cutting it out of metal.

Gasket with Cutout and Large Holes - The master cylinder has two metal inserts which are embossed from the surface. The large holes clear these inserts, so they don't squeeze the gasket.

Gasket with Cutout and Small Holes - This is here for completeness, maybe someone needs it if the master cylinder does not have embossed inserts.

Gasket without Cutout and Small Holes - For cover washers made from this model, this is the correct gasket to use.

Gasket without Cutout and Large Holes - This is here because I don't know if the original cover washer has the same type of metal inserts or not.

Print Settings

• I do not recommend printing the cover washer out of plastic. It holds part of your pedal assembly. Even though it wouldn't be critical if this part fails, it wouldn't be good either.
• IF you want to print it, use something strong like PC-CF.
•  
• TPE is probably a better material choice for the gasket than TPU, because it is not hygroscopic.
• Three outer perimeters, high infill (~80%)
• ≤0.2mm layer height

Please consider liking and posting a make if you find this useful 🙂