Yaesu FT-991A Protective Side Rail and Handle

After searching current designs on all the Yaesu FT-991A rails that I could print on the bamboo X1 I found most of the designs that I could print would either printing in an orientation I didn't feel was very strong or required glue or some kind of mechanical joint that also looked to reduce the strength of the rails. None of the designs really seemed to be as robust as one that could be printed as a single piece on a larger bed.

What I've come up with is the two-part design that fits together by friction and uses the case as well as the design to prevent the two parts from rotating. I printed in PETG HF, 3 walls, 25% gyroid infill,  and may eventually print in glass filled ABS if I break a part or add a feature.  

The print profile uploaded uses fuzzy skin (0.1mm, 0.1mm) which makes for a very tight fit. I found the only way to get the two parts together was to use the layer lines as interface guide interfaces and slide the two parts together as shown in the photographs. They came together smooth and snug, and the extra 0.2mm between the mounting holes did not affect fitment to the radio.  The holes for the mounting bolts (4x M4, 12mm L) also got tight on my first and only print, but using an impact driver on low setting and the heat from friction got them through.  I enlarged the holes for the individual model files to 4.3mm, the print profile holes are 4.2mm.

I am aware this is not the most robust design, and I honestly don’t intend on testing their performance.   CNC material, steel, aluminum or even plastic will certainly handle more abuse; the hope is these WILL “fail” if put to the task of drop protection, but fail in a way that still protects like a cycling helmet; “one crash protection”.   Re-print the part(s) that break.

I hope it's a pretty decent design, though I know there's some additional improvements that could be made, a short list to include:

• a microphone stow solution 
• additional accessory mounts
• slightly thicker handles(no sure if necessary)

I may continue to tweak and will upload any revisions, however I would encourage anyone to remix this model, make additions and post - I look forward to seeing what the others bring to the table.