DIY 360/430 Lateral Capote Flap (66462000 and 66462100) in CNC machined Aluminium for 75%+ discount

[b12LeSuppo 9]

I got banned from Ferrarichat for posting a DIY project I did, which clearly impacted Ricambi's business (Ricambi seems to be the main sponsor of FerrariChat...), Ferrarichat claiming that I was banned for "You have been banned for the following reason: Commercial sales", which I was not as everything in the chat there and the chat below is 100% and I have 0 commercial benefit in all this. By principle I refuse this behavior when what I did was just retroengineer a Ferrari flap for my own car with my own money and my own time.

 

So in the below you will get:

 - File to get CNC machined your own tool for the 355 and 360 belts, known as tool AV2938 (https://drive.google.com/file/d/16-k_unw3gU3rQ4BhURBdjV3hmkeQajog/view?usp=drive_link) get this tool for c. USD 30-40

 - File to get 3d Printed in Nylon your own 360/430 Spider roof flap holder references 66458800 and 66458700

 - The original 3D scan file of my own 360 Spider flap (66462100) should you want to retro-engineer one yourself

 - a pdf explaining every single step I took, from 3D snanning, cleaning the file, retro-engineering the flaps, getting quotes from CNC makers, getting the parts in less time that expected, showing the parts I received, fitting them on my car and comparing vs the OEM flaps.

 

So here is the way to save over 80% over what Ferrari charges or what Ricambi charges for the Lateral Capote Flap (66462000 and 66462100), and you will get a CNC machined aluminium part rather than the OEM fiber glass part.

 

Basically I damaged one of my OEM flaps on my 360 Spider and decided to make it myself, so went to rent a 3D scanner, scanned the non-broken flap, retro-engineered it, sent the file to a Chinese CNC manufacturer and got 2 brand new flaps, made of aluminium.

Result: 2 flaps CNC machined in Aluminium 6061 for USD 271 (ex shipping, ex VAT)

This is a 76-86% discount vs the Eurospare aluminium manufactured flaps and the OEM flaps respectively (shipping excluded) available at Ricambi and Eurospares,.

 

 - Ferrari 360/430 Spider Lateral Deflector (66462000  and 66462100) now cost GBP 528 + VAT each, and then need top be painted.

 - Eurospares also has “Eurospares Approved part” (which I understand are made out of aluminium) and cost GBP 425 + VAT, and then need top be painted. (Based on an FerrariChat discussions, these Eurospares flaps were c. GBP 309.75 in January 2024.)

 

Beyond the unregular accidental breaking, these OEM flaps, made out of fiber glass I believe, age badly and start cracking, in particular at the attach points.

 

My result:

 - Left: my DIY aluminium CNC machined flap for USD 135 (ex VAT and ex-shipping)

 - Right: The OEM flap that was used for the 3D scanning

 

 

Also, based on my 3D printing of the holder (see below) in "MJF heat resistant nylon", I must say that this MJF technique could be a very viable option for the Flap themselves as printing these in MJC PA12-HP Nylon would cost c. USD 25 and the surface is very nice. I have no idea how it would hold over the year though.

 

I also decided, just for fun, to get the support lever (Parts 66458700 and 66458800) professionally 3D printed (using the MJF technology) out of heat-resistant nylon for USD 1.64 per item, i.e. 98-99% cheaper than OEM parts (GBP 64 + VAT for c. 5g of plastic… real joke), and I provide the files below to allow anyone to get the same supports for cheap since these retro-engineered parts are not commercially available as far as I know.

 

The full detailed process and prices/links can be found in the pdf attached.

 

Just to give you a feel of what I received today below and compare it to the great work of Eurospares (I admit theirs seems 99.9% identical to the OEM one – for mine, I simplified on the non-visible part to make CNC machining a tiny bit easier - link to the Eurospares approved aluminium part for your reference: https://www.eurospares.co.uk/Parts/66462000/Eurospares?pi=68203):

 

 

I also got 3D printed in heat resistant Nylon using the MJF technology the flap holder (Ferrari part number 66458700) and was blown away by what I received (except the hole was too small, but my fault, so drilled it with 6mm drill bit and was fixed (and I corrected the file in this chat). 

 

 

 

Important Note:

Out of respect for Eurospare’s efforts in supporting the Ferrari community I am not posting here, nor will I make them available, the files that would allow anyone to get these flaps CNC machined directly for a fraction of what they cost to buy them from Eurospare.

Side-note to Eurospare though: it is hard to understand the 37% price increase in their flaps in just 1.5 years and knowing that manufacturing my retro-engineered flaps 20 pieces at a time would cost USD 104 a piece (based on the quote I received from the same manufacturer who did my flap, ex shipping ex VAT). It would be great if Eurospare could either sell the to-be-painted aluminium part for GBP 150-200, and/or sell a PPG painted part for their current price of GBP 425 so we can directly fit these in our cars because painting these is actually a pain, and the cost of painting 20 vs painting 1 is almost the same. Hope Eurospare considers this suggestion, thanks ;o).

 

However, I post below the following 4 links that will make anyone, with a bit of patience and effort, able to do exactly the same retro-engineering I did for free (caveat is that I used my cheap USD 200-300 Anycubic Kobra 2 3D printer to check fit before sending file for CNC machining):

 

Flaps :

 - Original 3D scan of my own OEM Left Deflector (Parts 66462000 and 66462100)

https://drive.google.com/file/d/1a24p6MXrsRGXlq-i5CQpUUzI2ClC7ODi/view?usp=drive_link

Accessing a quality 3D scanner is probably the biggest bottle-neck of this exercise and I was lucky to get access to what I think is a good one for only CHF 10 (USD 12)

This is the original 2.5 million triangle scan – c. 100Mb to download

Based on this 3D scan you should be able to retro-engineer your own Deflector(s) and get them CNC machined for a fraction of the cost of what the alternatives would cost

 

Flap Holder:

 - Left Flap Holder (retro-engineering of part 66458700)  - Retro-engineered by me, no guarantee it will last long

https://drive.google.com/file/d/1rTG8yfV8cTm2pwnj23I0eV3qeyaWK3p0/view?usp=drive_link

If you send this STEP file to a 3D printer, you should get the same flap holder that I ordered for less than USD 2

 

 - Right Flap Holder (retro-engineering of part 66458800) - Retro-engineered by me, no guarantee it will work fine  or last long

This is a pure symmetrical exact copy of the link above – USD 2 to get it 3D printed in heat resistant nylon

https://drive.google.com/file/d/1SO_Npo3L4pUUwS6Gsjcp1ZULR-0sQzGk/view?usp=drive_link

 

 - 3D scan of my own Left Flap Holder (Part 66458700) should you not like my retro-engineered version of it and want to retro-engineer your own left or right part and get it CNC machined or 3D printed for a couple of USD. Warning, for some reason the file has the wrong dimension and is 10x bigger than should be, so make sure you shrink by a factor 10 once done with retro-engineering to get a part c. 6cm high.

https://drive.google.com/file/d/1k6B57L_eYkcROGQ1RFUAaTjVHdTjy1GF/view?usp=drive_link

 

 

Flap Manufacturing Process - Published on Ferrari Chat (1).pdf

Modifié il y a 20 heures par b12LeSuppo

[oxygen 95]

Superbe travail !

 

j avais une fois envisagé la même chose pour les caches de lave phare. Sans aucune compétence en la matière ça s était arrêté là. cette pièce pourrait elle être un candidat à l exercise ? Dernier prix en date 65€ HT l unité (OEM)

Modifié il y a 10 heures par oxygen

[b12LeSuppo 9]

1 hour ago, oxygen said:

Superbe travail !

 

j avais une fois envisagé la même chose pour les caches de lave phare. Sans aucune compétence en la matière ça s était arrêté là. cette pièce pourrait elle être un candidat à l exercise ? Dernier prix en date 65€ HT l unité (OEM)

 

Hmmm, cette piece m'a l'air d'etre une bonne daube a retro-engineerer... en plus, j'ai aussi ces laves phares sur la mienne, mais ne les ai jamais active ;o)

 

Perso je vois ces parts (65896500 et 65896400) en OEM chez Eurospare a GBP 35.13 + VAT, donc pas certain que cela fasse enormement de sens de les retroengineer, mais le jour ou Ferrari arretera de produire ces parts, on sera pret ;o) 

 

Si tu veux, je peux essayer de la scanner avec le scanner que j'ai utilise (on a un youth centre qui le loue pour CHF 10 de l'heure et 1h est totalement suffisant pour le scanner) et essayer de le reproduire en CAD.

Il faudrait juste que tu m'en envoie un (le plus clean / sans partie abimee) par la poste en Suisse car pour etre honnete j'ai aucune envie de m'embeter a demonter un des miens / risquer de le casser LOL. Dis moi si c'est une option pour toi.

 

Sinon pour le mode de production:  

 - CNC machined en alu: perso j'oublierait cette methode car (1) tu as besoin d'un peu de flex pour les attaches, et (2) tu es oblige d'utiliser un CNC avec 5 axes qui augmente considerablement les cout, donc ta cover reviendrait probablement a EUR 30-40.

 -  3D printing en methode MJF: j'ai franchement hallucine par la qualite que j'ai recu pour mon flap holder, je ne m'attendais pas a ca. Vu les USD 1.64 que m'a coute le holder a produire, je dirais que la couverture reviendrait a probablement US$ 5. Le soucis principal que je vois au MJF Nylon est que la surface est un peu "grainy", mais vu que la surface est assez flat, avec un bon papier de verre a 300 grit, je pense que tu peux le rendre paintable en peu de temps