I was out and about over the lunch break Wednesday, and had a few moments to swing over and do a quick lot walk looking for headlight washer pumps.
I was looking for the BMW style because I know from experience they put out a decent flow through a small outlet orifice, they're compact, and they tend to never die. I would have also settled for Mazda, and I do have a spare in the basement, but I don't have the connector pigtail.
I lucked out and someone had already peeled back the pass fender on an E90 BMW 328i, so it was a few minutes to grab the headlight washer pump, windshield washer pump, both filter grommets, float switch from the reservoir, wiring, and the super awesome quick connect pressure hose up to the front bumper.
All that along with an aux power blanking cap (dummy cig lighter) and a USB/AUX center console input was under $20 out the door.
I'm a little annoyed I couldn't get the mating hose connector from the bumper, but the whole front end was literally missing, core support forward.
Printing a strainer/mounting adapter in PETG:
The brim gets plucked off later, it's there for extra bed adhesion/peace of mind, since it's a 2.5 hour print.
I haven't ran the printer since December last year, when I swapped control boards with a friend to get him the latest and greatest firmware flash on his machine.
Good excuse to use mine instead of pile things on it
The bulk of my actual printing experience came from printing ABS on his Makerbot Thing-O-Matic many moons ago, and I think I only ever printed a dice rolling tower and some misc quick upgrades in PLA.
I decided to go PETG because PLA or ABS would degrade in bilge conditions with oil/microbe/fuel vapor/water. Already had the filament from a BOGO sale event, so overall this is cheap.
It's a bit gooey/stringy, but it prints rather well.
Version 1.0 fresh off the printer.
The filter grommet slips in and the pump snaps on like the OEM washer jug for this version.
I could have used it as-is, but I was so anxious to get it printed I forgot mounting provisions. I also figured I could capture the pump a bit tighter, and go for a "bolt action" setup since I found it will drop in and twist easier than snapping in.
Those changes were made on V2, with mounting screw holes on the underside of the strainer. I also decoded to also add a middle ring halfway up the strainer slats to add some more rigidity, and a bit more wraparound on the pump body.
It's printing overnight, and hopefully didn't turn into spaghetti.
As far as control, it's going to be switched by hand for the moment. I'll be scrounging up a some random stuff I have laying around to make a little init to sense the float switch and cycle the pump as required, including a purge timer that kicks off after a few minutes if the float sticks, and a startup delay to avoid it triggering from normal riding.
The bathtub test with the jump pack had water nearly hit the ceiling, emptying a 2 gallon pail in under a minute through a 6mm(?) hose fitting.
Didn't think to stopwatch it.
The fitting to the outside world will take some thought, since I really, real, really don't want to punch a hole in the hull unless I have to.
Quite possibly I'll rig something up so it piddles out the back under the grab handle, right above the factory engine piddlers.
Modeling was done in Inventor, slicing was done in Cura from an exported .STL file.
Pics of the pump, filter grommet, and hose if I remember to take them.
