Charge Port Cover Dent Prevention – 3D Printed DIY Solution

[dtbaker61]

A few weeks back at the #NationalMustangDay event in Detroit, @JWW mentioned an incident with a basketball led to hyper-extension of his MME charge port cover and made a dent just forward of the charge port cover. I immediately set to looking for a preventative solution. Unfortunately, before I could complete my quest, our MME suffered a similar, but less dramatic fate. We don't even know how it happened other than perhaps it was very windy one day when we using a DC fast charger. We're going to need to get the dent fixed, but I wanted to make sure that we had a solution to prevent a re-occurrence, before taking any action.

Fast forward to now. I have developed a 3D model for an insert that adds a small wedge on the inside of the charge port arm to prevent it from opening too far.
Sure you could still body slam it and overcome the wedge, but you'll probably break the cover off before that happens.

I'll post the 3D model later, but for now here are the pics of the finished design. This has to be printed in TPU or similar flexible material with a shore hardness rating of 85A-90A or it can't be finagled into position. Installation has to be done with the charge port cover closed as much as possible, while working the wedge into place, then after that it's pretty easy to insert the upper and lower retaining wings.

Video showing installation + usage:

Sell this sucker to Ford!
(file a cheap 'patent pending', and sell the design to Ford, and get Royalties!)

I think this would be an awesome 'present' from Ford if they sent one of these, and maybe a T-shirt to all 2021 Mach-e Owners along with an actual survey to encourage detailed Feedback to be considered for 2022 model tweaks.

 

[jsteach]

Sell this sucker to Ford!
(file a cheap 'patent pending', and sell the design to Ford, and get Royalties!)

I think this would be an awesome 'present' from Ford if they sent one of these, and maybe a T-shirt to all 2021 Mach-e Owners along with an actual survey to encourage detailed Feedback to be considered for 2022 model tweaks.

Ford could add a bump stop to the hinge anytime the want. Its their door!!!

 

[BMT1071]

I've uploaded the video showing installation and usage of the part. It's only a little over 2 minutes long.

Perhaps a bit of soapy water applied to the wedge end would make sliding it in easier.

 

[Ponypower50]

I agree with jsteach all it needs is a rubber stop. If you took off the door hinge, installed the rubber stop to the framing your good to go. You could also install a rubber stop much like what's on the tail gate but smaller. They are adjustable to aline the rear hatch.

 

[MrRongoose]

So I just picked mine up yesterday and in my port, there's a small black rubber stopper that keeps the door just off 90. Do you think they added it? I can get a picture later.

 

[BMT1071]

So I just picked mine up yesterday and in my port, there's a small black rubber stopper that keeps the door just off 90. Do you think they added it? I can get a picture later.

It wouldn't surprise me if Ford made a running change to production. A forum member posted about a conversation he had with a Ford exec or engineer at an event and the Ford guy was shocked that the door could hit the fender and took some pictures.

 

[jsteach]

So I just picked mine up yesterday and in my port, there's a small black rubber stopper that keeps the door just off 90. Do you think they added it? I can get a picture later.

absolutely !!!!!

 

[jsteach]

Just checked. Here one!@@

 

[MrRongoose]

Just checked. Here one!@@

Yes, exactly what mine has!

 

[generaltso]

Just checked. Here one!@@

Mine has that too. I think that's just the regular stopper that makes it stop there in regular operation. But it doesn't take much to hyper-extend it past that point.

 

[AEtherScythe]

I agree with jsteach all it needs is a rubber stop. If you took off the door hinge, installed the rubber stop to the framing your good to go. You could also install a rubber stop much like what's on the tail gate but smaller. They are adjustable to aline the rear hatch.

Have you tried any of these things?
Tell us all how to get a stopper in there, please?
Tell us how to take off the door hinge?

 

[AEtherScythe]

It wouldn't surprise me if Ford made a running change to production. A forum member posted about a conversation he had with a Ford exec or engineer at an event and the Ford guy was shocked that the door could hit the fender and took some pictures.

I was there. Same event.

 

[AEtherScythe]

Just checked. Here one!@@

I have this same detent. I even tried to use it in an earlier prototype to keep the wedge in place.
That detent is in no way in contact with the charge port door arm.
It serves no useful purpose that I can see.

 

[MrRongoose]

I have this same detent. I even tried to use it in an earlier prototype to keep the wedge in place.
That detent is in no way in contact with the charge port door arm.
It serves no useful purpose that I can see.

Mine definitely stops the door early. I can hyperextend it yes, but it takes a decent amount of force. Enough force, that I wouldn't call it a design defect. Maybe minor inconsistencies in production with where that rubber is

 

[BMT1071]

I was there. Same event.

My enthusiasm about the 'new' bumper disappeared once the pic was posted.

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