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SR Suntour fork top cap socket (FAA122 replacement)

Creation's quality: 5.0/5 (1 vote)
Evaluation of members on the printability, utility, level of detail, etc.

3D model description

I recently attended bike tech workshops through the Professional Bike Mechanics Association (PBMA) where I received training in a whole bunch of different things from many different brands. I was constantly thinking "I bet I can 3D print that" and this is the first of several things I'll be posting which were inspired by these seminars.

SR Suntour makes a wide range of forks, but most folks have seen their forks in the form of the heavy steel forks like the XCT which are found on many entry-level bikes, mountain bikes, hybrids, etc. I previously thought of these forks as pretty low quality, but that's not fair, or accurate. Turns out that they are inexpensive, but they also have some brilliant features that make them completely serviceable. In particular, the design of the bushings is brilliant, they can be removed with a screwdriver and quickly replaced. To do this maintenance, you need the FAA122 tool, which you can see in the photos. Considering the FAA122 is plastic, I immediately saw the possibility of printing one, and at that point, turning it into a socket seemed like the obvious way to go.

The torque spec on the socket is only 10 Nm, and with so many points of engagement on the splines, this tool can handle that easily. I could probably even print it with a 3/8" socket drive and not have issues, but the 1/2" is stronger as it spreads the drive forces over a larger radius, thus reducing the stress on the socket.

Thanks to Jon Wells of Envelo for his help in this project!

Fusion 360 F3D file included if you want to change anything.

  • 3D file format: F3D and STL
  • Publication date: 2020/01/30 at 02:57



Designs 187
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Note: I wanted to try Cults3D as a possible alternative to Thingiverse, but after giving it a bit of a look, I'm not super impressed. Feel free to visit my Thingiverse page if they can manage to keep that site running:

I went to school as a mechanical engineer, and got interested in 3D modeling, specifically the SDRC I-DEAS CAD/CAM software system. This interest got me my first job working for a CAD/CAM reseller doing pre and post-sales support. I was lucky to be involved in 3D printing in the early 90s - for a demo of rapid prototyping, I modeled the mouse from my HP-UX CAD workstation and it was rendered via stereolithography. I still have that model, but across the years I stopped using CAD and moved to systems administration. Now that 3D printing is affordable and mostly reliable, I've gotten into it and am having a blast. I printed all the usual cute little trinkets and tchotchkes, but quickly got bored of that. What I find most interesting is needing something, then spending a little bit of time in a CAD program and soon after that having a real, functional version of the part in my hand.

I'm a cyclist and bike mechanic as a hobby and a side job, and have found endless applications of 3D printing to both bikes and bike maintenance. Coworkers have also come to me with many varied requests, each of which has been an interesting challenge and an opportunity to learn.

I am constantly learning, constantly trying to challenge myself to learn new things and technologies, so hopefully as I progress my designs will continue to improve.



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