Cave Diving Reel - Version for 100m and 150m Caveline

This is a diving reel for cave diving. It includes 6 parts that need 3D printing and two metal plates (ideally 2D manufactured) to avoid any abrasion of the line outlet. Everything is assembled with screws and bolts. There are two versions which can be equipped with either 100m or with 150m of caveline.

The files include the Autodesk Fusion 360 parametric design file, then all object as .stl and also as .step files, for both versions.

3D Printed Parts (I recommend to use igus iglidur filament to minimize friction and abrasion, but others should work fine):

• Spool wall (outer)
• Spool wall (inner)
• Drum
• Handle
• Knob
• Line Stopper
  I printed these things on a Bambu X1C with the igus i150 iglidur filament in the 0.2mm Strength profile.

2D Manufacturing/Milling

• 2x Metal plate (e.g. from bulk material, 20mm wide, 2 mm thick, I took brass but any metal should work, just keep in mind the corrosion)

Assembly Materials

• M6x20 flat head bolt (for knob)
• M6 lock nut
• 6 times 4x20 flat head screws (for spool walls to drum)
• M10x60 socket head bolt, partially threaded (rotating shaft)
• M10 lock nut
• M5x20 thumb screw
• M5 nut (no lock)
• super glue/loctite (fix the lock nuts in place and the bolts to it)
• silicone glue (fix metal plates to handle)

Additonally:

• Caveline (I used braided polyamid/nylon line with a thickness of 2mm)

Assembly Instructions

1. Use silicone glue to attach the metal plates on either side of the line outlet at the handle. Wait at least 24 hours to let it cure (ideally while applying pressure from both sides) before proceeding with step 4. Make sure the metal plates do not have any sharp edges where the line could get damaged.
2. With glue, the M6x20 bolt and M6 lock nut, fix the knob to the outer spool wall. Do not tighten it all the way, but almost to allow for rotation. Wait until the glue cures.
3. Screw in all 4x20 flat screws, attaching the spool walls to the drum.
4. With glue, fix the M10 lock nut in the handle. Insert the M10 bolt through the drum (socket head at the outside) and screw it in the M10 lock nut. I recommend using some glue just to be sure it does not get loose. Wait until the glue cures.
5. Insert the M5 nut into the slot where the locking mechanism is.
6. Screw in the thumb screw.

Instructions for Placing Line on the Reel:

1. Insert FIRST through the line outlet and then through the two holes in the outer spool wall and tie a knot.
2. Wind up as much line as you want. For the 100m version, approx. up to 120m can fit on it if it is filled completely. For the 150m version, approx. 170m. It is not recommended to fill it completely though as this generates a lot of friction. Please see the photos I attached. There you can see how the reels look with 100m and 150m of cave line.
3. Once you reach the desired length, cut the line, leaving 60cm from the line outlet. Place the line stopper on the line and tie a simple knot, creating a loop that fits the reel and accommodates the line stopper.
4. Now place all the line on the reel until the line stopper reaches the line outlet. Tighten the thumb screw and you are done!