Charge Port Cover Dent Prevention – 3D Printed DIY Solution

[jsteach]

Thanks, that is good advice. As of now it’s fine, I honestly had forgotten about it. I thought that being on one of the raised body lines might cause an issue vs a standard dent on a flat section.

Flat is much easier. Some of the great guys can do a good job on body lines.

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[Kamuelaflyer]

There are some fabulous painless dent removal guys out there. I would do a yelp check in your area and find ones with a few hundred 5 star reviews. If you drive there to fix $100.00 or less. If he come to you $125.00 to $150.00

Paintless dent repair is great. We had it done on a dent on our Raptor. You cannot see it. Well worth the money.

 

[Brian-e]

I printed with PLA and the tabs broke off trying to install it. I did manage to get part of it installed but it may be useless??

 

[BMT1071]

I printed with PLA and the tabs broke off trying to install it. I did manage to get part of it installed but it may be useless??

Well you've got the business end installed, but without the tabs it seems like it will fall off in short order.

 

[ebeponyan]

I printed with PLA and the tabs broke off trying to install it. I did manage to get part of it installed but it may be useless??

Duct tape time?

 

[Murse-In-Airy]

Thank you for posting a link to the STL. Looking forward to checking it out. I am going to print a few out in the next week and keep some on hand for any meetups, etc.

Would those be DOOR PRIZES??? ?

 

[Valkyrja]

I printed with PLA and the tabs broke off trying to install it. I did manage to get part of it installed but it may be useless??

Earlier in the thread I brought up about other filament types. TPU works the best but if you do not have a direct drive 3d printer you will not be able to print with it due to how soft the material is. PLA has heat tolerance issues. I think about 140*F is its glass transition state.

 

[ebeponyan]

So I suggested duct tape as a joke, but as it turns out, duct tape is almost the perfect width at 48mm to build this whole assembly. It also possesses both the strength to function and the flexibility to install.

I bet if you spend more than a few minutes on your lunch break tightening up the clearances (like taping directly around the arm instead of running a band), this would go from plausibly viable to entirely practical for folks without access to a printer. Full disclosure, I am not keeping this installed permamently. It looks as bad as you'd expect. But with some nice black tape? Maybe that would be worth the peace of mind.

Applying as much force as I am comfortable with here, and the door remains at a safe distance:

 

[AndyR]

Quick note: I checked Shapeways and this could be printed in SLS-TPU for about $30. $45 including shipping and processing.

 

[jsteach]

Quick note: I checked Shapeways and this could be printed in SLS-TPU for about $30. $45 including shipping and processing.

A friend of mine is a 3d printer extraordinaire he has 20 printers and more going full time .
He is making a few for me, Should have them early next week. I will follow up. I'm thinking
around $10.00 shipped . Printer is opening up on sat.

 

[AEtherScythe]

I printed with PLA and the tabs broke off trying to install it. I did manage to get part of it installed but it may be useless??

As you learned, PLA is not flexible. Without the retaining tabs, you're liable to "lose" the part inside and get it stuck in such a way that it would be very hard to get out and regain function of the door.

 

[AEtherScythe]

Quick note: I checked Shapeways and this could be printed in SLS-TPU for about $30. $45 including shipping and processing.

Yes, they're a very good provider and my samples are on the way already. But Shapeways are also double the cost of another provider who I'll mention if things work out with them.

 

[Larry]

Has anyone tried accessing the hinge from inside the fender? I know it would be some work to take the trim out from inside the frunk, but I’d be curious if there was a way to install a pin in the hinge that would prevent the door from opening past a certain point.

Take this with a huge grain of salt. I don’t have my MME yet so I’m just looking at pictures.

The Emergency Response Guide has instructions for accessing the battery disconnect. I think I see the back of the door in the picture. Is there somebody with a car who is brave enough to remove that cover and find out if they get access to the back of the charging door?

 

[EELinneman]

A friend of mine is a 3d printer extraordinaire he has 20 printers and more going full time .
He is making a few for me, Should have them early next week. I will follow up. I'm thinking
around $10.00 shipped . Printer is opening up on sat.

Once you get a price finalized, please let us know. I'll venmo you $$ immediately. Great idea and maybe Ford should be buying these from you!

 

[Kadaman]

Is it possible to get the file? I am in Norway and we can also use them. If you are selling the pet pls let me know the details

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