Plastic Insert for Shimano R540 SPD-SL Pedals

Some of the cheaper Shimano SPD-SL (PD-R540) pedals have a plastic insert / body cover that the cleat on the rider’s shoes rest on. These get worn down over time and as a result the connection of the shoe to the pedal starts to feel sloppy.

This is a 3d printable replacement.

At the time I was modelling / printing this, my printer had a partially blocked nozzle without me recognizing it. As a result, the perimeters on the flat side did not adhere to the infill and promptly got ripped off within minutes of riding.

In the end, as well as cleaning the nozzle, I disabled perimeters in slic3r globally and used a modifier mesh to reinstate them for the upper layers (clip parts and posts). See the screenshots.

The inserts have survived around 80km at this stage, but I am not sure how durable they will be in the long term – they are a consumable part.

I printed this with ABS to hopefully survive, but other materials may work just as well.