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I saw that I just did not know what the plan for the hole is.
We don’t have a plan just yet. One idea we had was use the bolt to hold the cover in so couldn’t pop off. So basically a mushroom design. Tricky part like others have said are contours of bumper and small lip. Hopefully have something end of next week.
We don’t have a plan just yet. One idea we had was use the bolt to hold the cover in so couldn’t pop off. So basically a mushroom design. Tricky part like others have said are contours of bumper and small lip. Hopefully have something end of next week.
I understand...a few of us have been talking about designs for these for a LONG time! But yes, the bumper is not flat and the holes are not squared-up with the edges so it is not as easy as it may first appear to be!
I ordered these to fill the holes for my G550 brush guard and it looks great. I'm happy to post pictures if needed www.caplugs.com and the part# is RER-1 1/2x2-10-14:
I ordered these to fill the holes for my G550 brush guard and it looks great. I'm happy to post pictures if needed www.caplugs.com and the part# is RER-1 1/2x2-10-14:
I ordered these to fill the holes for my G550 brush guard and it looks great. I'm happy to post pictures if needed www.caplugs.com and the part# is RER-1 1/2x2-10-14:
That's smart!! Yes would love to see how it looks if you don't mind. Does it wobble at all?
I made these and I am producing other pairs with no glue showing on the edges. I have upgraded my entire front end to a g63 facade and, therefore, I am selling these and the other 2 of the 3 pairs I am currently making. They look like a factory part when installed and can be painted to match the color of the car or stay black. The inside is the same rubber as the plug so entirely pliable and easy to get in and out as well as waterproof. Obviously, these are dirty as I just pulled them off my bumper when I swapped out the front end.
I ordered these to fill the holes for my G550 brush guard and it looks great. I'm happy to post pictures if needed www.caplugs.com and the part# is RER-1 1/2x2-10-14:
Thanks for finding these. I had asked 4 months ago in this thread for the bumper hole dimensions so I could search caplugs's catalog for a suitable part but nobody ever posted any numbers. I wasn't going to yank my guard off just to measure an opening.
So I'm still around, but have not had time to dig back into these with being swamped at work and never-ending house renovation projects.
The openings are roughly 80mm x 65mm. Finding something slightly smaller than that may work, but the lip area on top of the bumper is very small.
The main issue is the cutout is not rectangular, nor do the cutout sides match the bumper body lines. I have figured out everything up to this point. The last part is the most difficult, the mating surface is not flat, thus 3D printing something becomes much more difficult to get a good surface finish (using FDM). I have a few ideas, but have not had the 10 or so hours to devote to this on top of the 30-40 or so I have already put into the design.
I ordered these to fill the holes for my G550 brush guard and it looks great. I'm happy to post pictures if needed www.caplugs.com and the part# is RER-1 1/2x2-10-14:
Just wanted to double-check the item number, as Shiann ⬆️ says the hole is about 80mm x 65mm; whereas that item, per caplugs, is 38mm x 50mm.
I've been working on bumper plugs for those with W463A 2019+ G550 US Spec trucks that want to remove their front brush guards. These have been several months and several iterations in the making. Until recently, there was no solution (besides custom) for plugging up the hole left when removing the US-spec brush guard. I worked with BobZ (Thanks again for all your help!) to design a set of plugs that are 3D printed, that press and clip into the opening.
The plugs will come 3D printed using PET-G, which is a strong and stable plastic with better temperature properties and UV resistance compared to ABS. The parts will be raw 3D printed, so will have layer ridges, and will need to be finished smooth (sanding, priming, painting, clear).
The design looks like this. The plugs for the Driver's and Passenger's side are mirrored and follow the lines and curve of the bumper. There is also foam weather stripping under the front lip that sits against the bumper.
BobZ was awesome enough to take pictures after install with his truck. Below are a few different angles of the plugs installed. As you can see, the plugs are raised slightly from the bumper (with foam gasket) and are slightly domed. They are not flat and do not sit flat to the bumper.
This is what the plugs will look like in their raw 3D printed state (FDM Printer). These pastic parts will finish like any other plastic part. Sanding smooth is the same difficulty as any other plastic and painting will require adhesion promotor or plastic-specific paint.
Currently, I am looking for someone in the NJ/NY/PA/CT area who is looking to remove their brush bar, so I can do final test fitting to ensure the part fits as exact as it can. I have the ability to adjust the design ever so slightly if needed since I designed them.
A member in the DC area contact me and is willing to help and will try to arrange for that in the near future, if there isn't anyone closer.
I 3D print these myself and custom built/maintain my printer so production time will be on an order by order basis. Print time is 1 set per night (12 hours print time). Shipping will be done by USPS priority small box, which usually takes 3-5 days depending on where you live in the country.
If there is interest, please start a running list here and when these are perfect, I will let everyone know.
I have a price in mind factoring in the printing time, material cost, and the time required to design. All without the add-on G tax.
Moderators, if this is against the rules, please let me know what I can do to not be in violation of the rules.
Thanks everyone!
Hello,
I’m in the Philly area and have removed my brush guard. I would like to try these plugs. Please contact me at 215-852-1822.
I have no affiliation with the above companies and/or parts. Nor do I know how they attach and/or how they fit/look. I saw them and they are simpler solutions than I was designing. Also, the price I was looking for the amount of work needed to make a set would not be far off the above part prices, so it doesn't make sense for me to offer another competing solution as I don't have enough time on my hands.
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