Dyson DC41 Power Cable Hook

A replacement cable hook for the Dyson DC41 vacuum cleaner. This part is quite thin and can snap off after time, but can be replaced reasonably easily.

The installation involved removing the cap covering the screw, which we reuse, and unscrewing the old one, taking the spring and transferring it into the new part, then screwing the new one in, tightening to adjust how easily it twists. Taking out the cap is the hard part, you will need a tool (e.g: a flathead screwdriver) to push into the gap and slowly work it out. The cap should push into place on the new model tightly, check the orientation is right: there is a small peg at the bottom that keys into a slot on the cap.

This design is thicker and has beefed up attachment to try and ensure strength, I also made it a little longer than the original, but maintained the angle the original has. It seems very solid, the cable wraps with it well.

I suggest plenty of wall loops and shell layers, and Gyroid 50% infill. You could probably use less but it's nice for it to be robust and it's small, so it's not a lot of material regardless. I also did a slower first layer to try and get a nice finish for the part you see. Should print happily without supports, I suggest PETG as PLA is a bit brittle for this use case. There is some bridging the PETG doesn't do perfectly, but it's all internal and covered by the cap in the end, and has no functional impact.

According to the Dyson website, the same wand is used by the Dyson Cinetic Big Ball, DC55, DC41 Mk2, and DC40, so if you have any of those, this may work for you, but I have not tested it with them.

Also included are STEP and original FreeCAD model files if you want to make changes, or maybe adjust for another model of vacuum.

Edit: After about a year the threads on the other side of the wand stripped out. You could just screw it in again cutting a new thread and hope, but it'll get weaker each time. I instead used an M3 6mm length / 5mm OD brass heat-set insert (you could use a shorter one, and I imagine 4.5mm OD would be fine too) and melted that into the existing hole. The existing screw has a large captive washer, you could somehow free it and reuse it or get an equivalent one and use a 12mm M3 screw, but I just printed a simple 14mm diameter, 5mm deep washer with a 3.6mm hole (easy to make in the slicer) and used that with a 16mm M3 screw. It worked great and seems very secure again.