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W463A G550 (2019+) US Spec Bumper Plug (Brush Guard Removal)
Hi Everyone,
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.
I really like these and at first I thought about getting them painted to match but after a few weeks I think I will leave them as-is since there is a lot of Black on the truck and they kind of blend in. After several weeks of driving with them on I have checked them periodically to be sure they have not wiggled out, etc. and there has been no movement at all so I am sure they will stay in place, unless one wants to take them out, which is easy using just your fingers. If someone has been thinking about removing the brush bar but was reluctant to do so this is a top notch option!
I really like these and at first I thought about getting them painted to match but after a few weeks I think I will leave them as-is since there is a lot of Black on the truck and they kind of blend in. After several weeks of driving with them on I have checked them periodically to be sure they have not wiggled out, etc. and there has been no movement at all so I am sure they will stay in place, unless one wants to take them out, which is easy using just your fingers. If someone has been thinking about removing the brush bar but was reluctant to do so this is a top notch option!
your truck definitely looks better without the brush guard.
I believe this would be a viable option (depending on any components mounted on the interior of the bumpers), or sourcing a front bumper from a Euro-spec or Canadian-Spec G550. The cost would probably be significant though, which is the point of just having plugs that can be installed and removed quickly.
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!
I’m in Ca but I’ll take a set ASAP! Fore that 3D printer up!
shiann - I've been 3D printing for only about a year, and have used mostly PLA filament like many others. I recently began experimenting with PETG filament, and have found it to be extremely finicky. It blobs and strings excessively, and is really difficult to work with IMO. There are probably a half dozen variables to play with, and likely I've just not happened upon the optimum combination of temperatures, extruder flow, fill %, etc. I set the PETG spool aside and loaded a spool of carbon fiber filament that I had not used before. Wow! The CF is amazing. I've printed a few items in high resolution (0.8mm) and high fill density (90%) and am impressed with the quality of the finished surface. It could be primed and painted without even requiring any pit filling or surface sanding. Print time is extraordinarily long (who cares - I'm sleeping) but the results are worth the time. Have you tried using carbon fiber for your bumper plugs?
Sorry for the lack of updates. Things have gotten pretty busy at work and in life so I haven't had that much time to work on side projects that don't have a deadline to complete before the winter fully arrives in the Northeast.
About 3 weeks ago, I met with a forum member and his W463A G550 with the brush guard removed. Thanks Saif! I was able to test fit the current design of the bumper plugs and although they fit ok overall, I wasn't completely happy with their fit and/or look.
A few issues to note:
1. The bumper has a slight curved shape that I'll need to add into the flanged part of the plug to fit 100%
2. The plug sat too high off the top surface of the bumper. I'll be slightly modifying to make the plug sit lower and also use a thinner foam gasket.
3. The lower attachment clips really don't work all that well. I'll be redesigning a lower bracket to attach the plug from below using screws. This way they will not fall out and be held in securely.
The plan is to finish the design this weekend and 3D print a few parts and assemble. I'll send these parts out to a few members I have been working with and once they verify the overall fit, they will be ready for sale.
Full disclosure, a G-specific vendor has also come out with a plug for the 2019+ G550 bumper. I have no clue how good it is, how it fits, what it's made of, etc. but some may prefer to buy from an established vendor.
Their price is $225 for a set that still needs to be sanded, finished, and painted.
I'm planning on my designed parts to be $100 shipped for the pair. They will still need to be sanded, finished, and painted also.
I talked to Shiann today and he has been very busy. I was one of the members here that helped him and I am running a set of his now that I really like but he is a perfectionist (I thought I was as well!) so he wants to tweak the design so people will like them even more. Anyway, stay patient a little while longer!
By the way, while I have your attention, those of you that expressed interest in the Tuxmat all-weather floor mats we may be able to order them in a couple weeks (fingers crossed)/
I haven't disappeared, just have had very little time to work on this the past few months. Will be devoting time to get it done in the next 2 weeks so stay tuned.
I'll be sending out a PM to those who have responded with interest in this thread to gather some more information.
I haven't disappeared, just have had very little time to work on this the past few months. Will be devoting time to get it done in the next 2 weeks so stay tuned.
I'll be sending out a PM to those who have responded with interest in this thread to gather some more information.
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