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Thanks, and a template is needed though. Again, you can probably use some stiff paper or something and if you tape it over it you can either use your fingers along the edge to crease the paper or use a pencil. Here is my address and I will pay the postage if need be:
I am talking to a couple 3D printing places now and they need a template of the size of the hole and the thickness of the bumper material (plastic or metal?) and I hope I can get an estimate of the cost. I am thinking it can be made out of a paintable plastic so we can match the bumpers, or just Obsidian Black for those of us that have the Night Packages.
I have back & forth with the 3D printer guy and I am willing to pay the initial fees (file and prototypes) if someone wants to be test vehicle; however, the same person needs to get me the exact size and shape of the holes, as well as the thickness of the bumper material the hole is in and how much flat space is available around the hole so we know how far we can overlap. We want to keep it to a minimum but we need to know how much room there is. I would suggest getting a piece of thin paper and taping it tightly over the hole, and using a pencil at an angle around the opening, or just use your finger and at an angle press against the opening edges all the way around to create a slight crease. I will then need it mailed to me (address in Post #77 so I can mail it to the 3D Printer person. I will free hand draw what my idea is and post it here tomorrow so everyone knows what I am thinking about, and at that time I will welcome suggestions.
Hi Bob,
I would be great if someone could create a rubber cover to replace the existing that accommodated the BB.
The dimensions of the opening without the existing cover is 3.25" x 2.5", with rounded corners (see photo).
Once I removed the BB I created a plug for the existing cover by cutting down a rubber/felt furniture pad and it seems to be effective, and somewhat weather proof (see photo).
I also ordered some plastic plugs that are used to cap the ends of metal posts, but they are slightly too short to completely fill the opening in the existing rubber cover (see photo).
Best solution would be to create an entirely new rubber/plastic plug/cover (3.25" x 2.5"). If not, the second solution would require creating a small rectangular plug/cover (2" x 1.5") that goes in the existing rubber cover, and in place of the BB, once it is removed. Left to Right - stock plastic plug 1.7/8"x1.3/8" (too short) Custom rubber/felt furniture pad - 2"x1.5" - (perfect fit) Existing rubber cover for G550 bumper
I have been searching for a plug to use without the rubber to use in the bumper hole but no luck thus far. And as I said, I am talking to a couple 3D printing places about making us a piece as well.
I took another impression of the hole left when the existing rubber cover is removed - I will mail to you today.
The measurement of the existing rubber cover appears to show an overlap of 1/8" on top of the bumper, and 3/8" overlap on the underside of the bumper, so it holds it in place when installed. The thickness of the steel bumper is 1/8" thick.
The interior cavity inside the bumper, with the BB removed, is deep all the way down (approx 5"-6" deep) so you can easily fit a 1" plug inside when the existing rubber cover is removed.
Let me know if you need anything else.
Perfect, thanks! In my last post I referenced a possible plug to be used with the rubber still in the bumper but if we got one that was 2" x 1 1/2" it would not be big enough to overlap but they have a 2" x 2 1/2" plug that should work.
One last question for now: when the rubber is removed, how much flat space is there around the perimeter of the hole? I say flat since if I get a piece made it will have to rest on the bumper, overlapping the hole a little bit; however, if the bumper starts to curve or taper the piece will not lie flat. It appears there is plenty of room on the left and right (when facing the hole from the front of the vehicle looking to the rear) but the top and bottom sides of the hole are the measurements I really need.
Perfect, thanks! In my last post I referenced a possible plug to be used with the rubber still in the bumper but if we got one that was 2" x 1 1/2" it would not be big enough to overlap but they have a 2" x 2 1/2" plug that should work.
(Response) Agreed - maybe a 2" x 2.5" plug might work, but slightly oversized in length and would require trimming of the existing rubber cover.
One last question for now: when the rubber is removed, how much flat space is there around the perimeter of the hole? I say flat since if I get a piece made it will have to rest on the bumper, overlapping the hole a little bit; however, if the bumper starts to curve or taper the piece will not lie flat. It appears there is plenty of room on the left and right (when facing the hole from the front of the vehicle looking to the rear) but the top and bottom sides of the hole are the measurements I really need.
(Response) There is approx 3/8" flat space on top (towards back of bumper) and 1/2" - 5/8" flat space on bottom (towards front of bumper).
On the underside of the bumper surrounding the hole there is at east the same dimensions of flat space.
Thanks. I ordered several free samples of plugs to be used with the rubber but since my G550 will not here for a while I will not be able to try them out! But when I get the info you sent me I will start working on my idea and post info here for feedback to see if there is interest in a 3D printed piece.
I took another impression of the hole left when the existing rubber cover is removed - I will mail to you today.
The measurement of the existing rubber cover appears to show an overlap of 1/8" on top of the bumper, and 3/8" overlap on the underside of the bumper, so it holds it in place when installed. The thickness of the steel bumper is 1/8" thick.
The interior cavity inside the bumper, with the BB removed, is deep all the way down (approx 5"-6" deep) so you can easily fit a 1" plug inside when the existing rubber cover is removed.
Let me know if you need anything else.
Max
Thanks much and I am looking into what can be made using bits and parts I have been picking up but to get a professional look we may have get a 3D part made. It would help if I had my G but it is a ways off!
cut your losses and just order these. A 180k truck and trying to rig something to fit for 2.00 is not the answer
They do not make any covers for the US version G550. I also spoke with them and verified it, thus the reason we are looking into cheap options since we cannot waste our money otherwise.
I had a local fabricator make these aluminum plates to fit in the remaining rubber covers. Works pretty well but still bizarre Mercedes doesn't have a solution for this.
Nice, and if he kept the dimensions maybe he could make them for others as well? Also, you could paint them to match the black rubber so they blend in.
I have a 3D printer and can help design the CAD file but will need a very accurate template and measurements from someone and also someone willing to test fit a few rounds of prototypes. PM me and we can figure something out. I did something very similar when making door speaker adapters on my G55 for aftermarket speakers. Final parts will need a gasket to not damage the paint, and can be 3D printed or CNC out of plastic or aluminum.
Those metal plates inserted into the factory rubber seals do look like a relatively simple and clean solution, and will certainly be cheaper than making a full custom plug.
I have a 3D printer and can help design the CAD file but will need a very accurate template and measurements from someone and also someone willing to test fit a few rounds of prototypes. PM me and we can figure something out. I did something very similar when making door speaker adapters on my G55 for aftermarket speakers. Final parts will need a gasket to not damage the paint, and can be 3D printed or CNC out of plastic or aluminum.
Those metal plates inserted into the factory rubber seals do look like a relatively simple and clean solution, and will certainly be cheaper than making a full custom plug.
I have a template of the holes (G550) from a member here that I can mail to you if need be, which is a piece of paper that he put over the top and pressed down on to make an imprint of the hole. I thought about a design as well (see attached). If the lip underneath were at least a 1/4" all around 3M tape could be used to affix it.
I have a template of the holes (G550) from a member here that I can mail to you if need be, which is a piece of paper that he put over the top and pressed down on to make an imprint of the hole. I thought about a design as well (see attached). If the lip underneath were at least a 1/4" all around 3M tape could be used to affix it.
Hey Bob,
Sorry for the delay. I had something come up that brought me away from my 3d printer, but back at it now. When do you get your truck?
I'll need someone with a W463A G550 with the brush guard removed to test fit in the hole. I will also need more details such as panel thickness for designing clips.
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