Logitech X52 Coolie Hat Replacement

The coolie hat of my old Logitech X52 hotas broke just while I was landing my space ship. After being annoyed for some seconds I designed a printable replacement.

Be warned - this repair is not for beginners. It includes small screws, tiny parts, soldering and a little bit of glue for the printed parts.

Print preparation:
Make sure that your print bed is clean and grease-free and use a quality brand and dry filament.

Print settings:
Use a 0.4mm nozzle with 0.2mm layer standard settings for PLA. The stem must be lying on its side to maximise strength. You will need supports. I recommend you use PETG for the support interface because it results in cleaner surfaces. But this is only optional. 
EDIT: After some testing I recommend to use PETG (or even ABS) for the model and PLA for the support interface. This adds a little bit of flexibility to the coolie hat. 
Slightly reduce the speed of the outer walls for a better quality. Use four walls to optimise stability.
See my print profile for more details.

Assembly:
Just glue the two parts together.
OPTIONAL: File a tiny groove into the 4mm square end of the stem for installation with a C-clip

Installation:
Now comes the hard part. Take a look at the pictures at the top to see some details.

• Remove the hand guard that includes the pinky switch. 
  One inner hex BT screw on bottom left and right, two inner hex metric bolts on the top
  Loosen the pinky level button and wiggle the hand guard out, no need to remove it completely

• Remove the right side of the handle by unscrewing four Phillips BT screws (top, middle, 2x bottom)

• Carefully slide out the trigger - there is a loose spring underneath and a loose plastic pin in the bottom of the trigger

• Slide out the complete upper half that includes all buttons and the coolie hats to the right

• Unplug the electrical connector of the upper half

• Unscrew the single bolt on the top metal bracket, then pull the bracket out to the front

• On the inside you can see top right a C-clip that is holding the coolie hat - remove it

• Pull out the coolie hat, that will reveal four tiny screws on the back of the hat

• Unscrew the four tiny screws and remove the LED carrier

• You can now see three wires attached to the LED board - de-solder them carefully

• Remove the broken stem 

• Insert the wires into the printed replacement part

• Solder the wires back to the LED board

• Screw the printed replacement part to the LED carrier

• Re-install your new coolie hat to the upper half of the joystick and secure it with the C-Clip

• Re-assembly everything in reverse order (take special care of the spring in the trigger - this one is nasty)

And now, back to the pilot's seat! 
o7, commanders!
 

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Disclaimer:
This work by blecheimer is licensed under CC BY-NC-SA 4.0. The shown model must not be used commercially.
Copying this model to other 3D printing websites is not allowed without my permission.