Printing A Replacement Deadbolt Lever

We’ve got a deadbolt on one of our doors with a locking lever that went missing about a month and a half ago. I haven’t been able to find a replacement lever so I decided to make one.


After measuring the stem I designed a parametric model for a lever replacement.


And then printed it out. It took me two tries since my initial measurements with the digital fractional calipers was off (first time using them).


Once I got the internal measurements correct the locking lever slide snugly over the stem and made it easier to lock the deadbolt. Voila, problem solved!


And if it’s ever lost or broken, I can print out as many replacements as I need.


Here’s the script to create the replacement lever.

outerLength = 30;
outerWidth = 10;
outerHeight = 8.68;</p>

<p>innerLength = 10.98;
innerWidth = 7.14;
innerHeight = 7.68;</p>

<p>xPosition = (outerLength - innerLength) - 1.96;
yPosition = (outerWidth - innerWidth) / 2;</p>

<p>difference() {
color("blue") cube(size=[outerLength, outerWidth, outerHeight]);
translate([xPosition, yPosition, 1.0])
color("red") cube(size=[innerLength, innerWidth, innerHeight]);

First we set the parameters for the lever’s overall dimensions (the “outers”) and then the space that we need to carve out in the lever so it can fit over the stem (the “inners”). Then, using the outer and inner lengths and widths we calculate the position of the inner cube and then use the translate command to position the inner cube in the correct place


We use OpenSCAD’s difference command to subtract the inner cube from the the outer cube.


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