Charge Port Cover Dent Prevention – 3D Printed DIY Solution

[LandSpeed]

Hot off the press, if you'd like to get the highest quality possible part with the black vapor finish, you can now just go here and place an order with JawsTec.
$20 plus $10 shipping on quantity one.

https://www.jawstec.com/product/wedge-mme-chargeport-door/

Thank you @AEtherScythe, et al.

Just ordered one.

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[JohnnyForensic]

I know through channels that Ford is aware of the issue (and my work), but I do not know if any change has been made to the actual charge port door assembly to mitigate the problem.

As I was filling my gas tank on my RDX (still in line for my MME, but build is about a week out!), I noted that the gas tank door opens the same way that the MME's charge port door does. For kicks, I pressed against it, and the edge of the door EASILY hit the side of the car while open. Noodling it through for a couple of seconds made me think really the only difference here is a fuel tank door is open for a few minutes under relatively controlled conditions (no bouncing basketballs in a gas pump lane usually), but a charge port door could be open for hours or days in a higher traffic garage or driveway, leading to a greater chance of interaction with something unintended. The use case between the two doors is nearly the same, but that one exception makes all the difference. Funny.

 

[woody]

Installed the JawsTech part.
The only difficulty is with the top tab. Hard to insert and sticks up a bit, car side. I did not want to shave it down, so I left it as is. The piece of the tab sticking up does not interfere.
It works.

 

[Kamuelaflyer]

Mine arrived today. Installed it after I finished charging in the garage. Nice exacting fi and should come in quite handy around here. This place does not lack for wind.

 

[Kamuelaflyer]

Installed the JawsTech part.
The only difficulty is with the top tab. Hard to insert and sticks up a bit, car side. I did not want to shave it down, so I left it as is. The piece of the tab sticking up does not interfere.
It works.

Use some water or speed shine or something on the tab sticking up. It's a very tight fit. One or two good sprays on the upper tabs and it'll fit.

 

[AEtherScythe]

Installed the JawsTech part.
The only difficulty is with the top tab. Hard to insert and sticks up a bit, car side. I did not want to shave it down, so I left it as is. The piece of the tab sticking up does not interfere.
It works.

Yes. Definitely tighter than the one I printed myself, but if you fit one edge of the top tab first it's doable. You should be able to finesse it all the way down/in. Worst case wait for winter and it will press right in. I was able to press mine all the way flush on a not too hot day, a few weeks back, before I posted the JawsTec link. Just be patient and take care with it. Cheers.

 

[markystarky]

I got mine. It took about 5 minutes to wiggle it into place. I like how when I press the door it now opens part way, and stops sooner than with out it.

 

[ocr_salty]

Has anyone sent this solution to Ford? It seems like a very cheap and simple factory/dealer fit solution to a serious problem that could ultimately result in a class action lawsuit (if it turns out to be a design flaw).

 

[AjzRide]

Has anyone sent this solution to Ford? It seems like a very cheap and simple factory/dealer fit solution to a serious problem that could ultimately result in a class action lawsuit (if it turns out to be a design flaw).

The better move for Ford would be to have the door swing upwards instead of sideways.

 

[Shayne]

I got mine. It took about 5 minutes to wiggle it into place. I like how when I press the door it now opens part way, and stops sooner than with out it.

Wow you got dinged a whole lot worse than me. Mine is not noticeable but could be quick. Thanks for sharing I also like the fact that when it pops it is not all the way. Think that will help with my error.

The better move for Ford would be to have the door swing upwards instead of sideways.

I thought that too like a little roof from the elements as it is open for extended periods. I think if it opens at speed by accident and it opens up it may flutter and create damage where it is located right now. Hidden in the rear end may work and open up at the down draft?

 

[Andeh]

Has anyone sent this solution to Ford? It seems like a very cheap and simple factory/dealer fit solution to a serious problem that could ultimately result in a class action lawsuit (if it turns out to be a design flaw).

A lawsuit, over a small ding? ? America really is the land of pointless litigation isn't it.

 

[davkd]

So far I've only had 3 people message me about printing one for them. I should be able to print 10 at a time, so don't be shy if you want one.

I would like one if you would consider posting to the UK?

If so just let me know how much.

Thanks

 

[AjzRide]

I would like one if you would consider posting to the UK?

If so just let me know how much.

Thanks

I have already checked and shipping from US to UK is more expensive than ordering one from a 3D printing service located in Europe.

 

[AEtherScythe]

I would like one if you would consider posting to the UK?

If so just let me know how much.

Thanks

Shapeways has a location in Europe. You could upload the part to them to have it printed in TPU via the SLS process. I would write to them about getting it in black with a vapor polished finish.
I ordered a sample here in the states and it was white and unfinished. Twice as expensive as the JawsTec.com one and 1/4 as nice. JawsTec will ship to you for $50, and for the money you're getting expedited processing (normally it takes 2 weeks for processing).

I bet you'll find that in total the JawsTec price for going that route will be cheaper than Shapeways.
Here is the link again:

https://www.jawstec.com/product/wedge-mme-chargeport-door/

 

[AEtherScythe]

This material from i.materialize.com, based in Belgium, might be another possibility for folks in Europe. This is TPU with a shore hardness rating of 88A, so it will be similar to the other TPU's I've sampled. Only difference is it's MJF process not SLS. MJF is also good. You can of course write them if they have TPU powder for their SLS machines.

https://i.materialise.com/en/3d-printing-materials/rubber-like/technical-specifications

They ship world-wide, too. I have not actually ordered a sample, so YMMV.

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