Custom Volvo Fob

Custom Volvo 5 and 6 Button Fob for Volvos - XC70 (2008-2016), XC60 (2009-2017), V70(2008-2016), S60 (2011-2017), S80 (2007-)

Replicates the key remote with 5 buttons and a single CR2430 battery or Dual CR2430 batteries and 6 buttons.

It might be not compatible with some fob chip clones/variants due to different dimensions or different component placement on the chip. Make sure it's suitable for your chip- check picture.

Please, be aware- for this fob to work you will need to make battery-chip connector out of a pen spring.

Assembly process: https://youtu.be/VpciuL1I7Oo

For dual color printing, you can read on guide below or follow this video guide: https://youtu.be/0Sla-vIsvh4

Warnings:

It's 3D printed case and even with TPU sealing it won't be as well sealed as the original part- avoid putting it in water, dirt, oils or any other contaminants.
Even though this remote case was made to fit the original (65957302) 5 button chip and adapted for 6 button chip too, you still need to use your common sense- there have been quite a few variations of a chip made during 2008-2017, original ones and clones from China. ALWAYS check if this case fits with your chip, and don't use brute force if you can't close it with a chip inside it- I WON'T be responsible if you damage your chip.

30659339, 30659499, 30659501, 30659636, 30659637, 31391409, 31419133

Print settings

Material: PLA, ABS, PETG... (ABS would serve best due to possible hot environment) and TPU (that is a MUST for better sealing)

Layer height: MUST be set at 0.12mm (otherwise essential parts will fuse or won't be printed at all)

All parts combined print time: about 4h 30min

s: if you choose to print version with s, parts have implemented s which will need to be removed, don't use autogenerated s or brim- it will mess up icons and keyhole.

Z Hop: at least 0,25mm or more (0,3mm recommended)

zip file includes various versions of shell (5 and 6 buttons, different logos, parts with s and without them, separate parts) choose which ones you want/need.

Printing guide (assuming it's Cura)

1. Align "top" with "keys" stl and "bottom" with the "logo" stl on a slicer (you might want to print "top" and "bottom" separately to get better quality and fewer blobs or together for less hustle while swapping and purging filament).
   Example: On "bottom" stl set its location to x:-30; y:0; z:0; and do the same on "logo" stl, while on "top" and "keys" stl set it to x:-30; y:0; z:0.

2. Delete "top" and "bottom" stl, leaving only "keys" and "logo" stl. Slice it, and save it to card, and don't forget to change gcode file name, so that it would not be replaced later on.

3. Click CTRL+Z (Undo) twice, it will return "top" and "bottom" stl back. Now delete "keys" and "logo" stl, leaving you with only "top" and "bottom" stl. Enable "Z hop" setting in a slicer and set it to 0.3mm. Slice it and save it to card.

4. First print "keys" and "logo" file. Once printed, check if logo/keys looks good, if not, reprint it, level the bed if needed.

5. Once "keys/logo" done (keep the bed hot), change the filament to a different color one, purge the nozel well and start printing "top/bottom" file.

6. Once done, clean s inside of the keyhole (read on or watch video). To do that, you will need toothpick or not so britle filament piece. Poke keyhole with a toothpick untill u able to shove it about 5 cm in. Once thats done, take pliers and pull out from the keyhole.

7. Print "seal" and "membrane" parts with TPU, apart 0,12mm layer height, it doesn't need any other special settings.

8. Find pen spring and shape it like in picture or watch the video.

9. Pay attention, check if everything fits nice and smooth and assamble everything:
   if its single battery in this order- spacer, spring, battery(negative side up) and chip.
   if its dual battery- spring, battery(positive side up), spring, battery(negative side up) and chip.
   TPU parts goes to top part (buttons).
   Check if everything aligns, if chip getting power, close the fob and thats all.

Assembly process: https://youtu.be/VpciuL1I7Oo