[diesel_dave]

I was getting annoyed at having to pop open the door and then remove the rubber port cover and then reinstall it so I could close the door (I know, lazy kids these days). I designed a prototype thingy that would stick onto the door and seal the charge port up when the door is closed so water and junk doesn't get in it. I printed it in flexible material (TPU) and I think it's a viable idea after messing around with it. I still need to get the dimensions worked out so that it seals tightly enough while the door is closed and doesn't keep the door from staying latched shut.

More to come. Just need time to work on it some more.

 

[SSTuner]

Great idea. Keep us posted.

 

[Stro4xe]

I would buy one!

 

[Sheepish Lord]

No doubt folks would buy them just for the lazy factor. If I had a Wrangler I probably wouldn’t even use the rubber thing unless I lived or planned to go in a dusty environment and would probably forget regardless.

 

[diesel_dave]

I would buy one!

Plan is to provide the 3d model so you can just make one yourself if you have a 3d printer. If folks don't have one (most probably don't), I might be able to make some and send them out for a few $.

I ended up changing the design for a more positive seal that doesn't rely on trying to seal against the outter face. Instead it seals against the walls of the port. It's printing now. Hopefully it's a better way to do it.

 

[diesel_dave]

No doubt folks would buy them just for the lazy factor. If I had a Wrangler I probably wouldn’t even use the rubber thing unless I lived or planned to go in a dusty environment and would probably forget regardless.

I've been driving around a few days with my rubber plug removed so I could measure it. Yeahhh it's not getting dirty at all in there so far with that plug removed. I'm sure if the weather was bad or I was going down trails junk would end up in there though.

 

[C.sco]

Pretty cool!

I'm wondering if it might be a good idea to put a soft foam ring/gasket on it here:

 

[FL4xe]

I was getting annoyed at having to pop open the door and then remove the rubber port cover and then reinstall it so I could close the door (I know, lazy kids these days). I designed a prototype thingy that would stick onto the door and seal the charge port up when the door is closed so water and junk doesn't get in it. I printed it in flexible material (TPU) and I think it's a viable idea after messing around with it. I still need to get the dimensions worked out so that it seals tightly enough while the door is closed and doesn't keep the door from staying latched shut.

More to come. Just need time to work on it some more.

View attachment 9685

View attachment 9686

View attachment 9687

Would it be possible to have the shroud go around the outside instead?
I would think it would be next to impossible for anything to find its way in then.
(Worst case would be to have a bit of foam in the outside rear of the charge port for an extra level of seal)

My wife is out with her 4xe so I don't have the opportunity to see if what I'm suggesting even makes sense.

 

[ttturner68]

Pretty cool!

I'm wondering if it might be a good idea to put a soft foam ring/gasket on it here:

View attachment 9696

TPU is already soft.

 

[diesel_dave]

TPU is pretty soft yes. Not quite rubber, but close. I have a new design printing that doesn't have that flange at all. It just sort of wedges into the gap between the inner charge port and the outter "shell" and looks more like this:

That's just a portion of the whole thing to get the dimensions right. This particular version's wall thickness was too thin so it didnt seal very tightly. A thicker one is printing now. Once I get that dialed in, I'll add the body that will allow it to stick to the door with 3M tape.

I thought I liked the flange style more, but after messing with it, I can see why it won't work well. The issue is when you close to door to latch it, it presses in like .25" and then goes back flush. That presents a problem with a flange type seal because it would need to deform enough to allow the door to close but then also still make a good seal when the door is flush. Probably didn't describe that well, but you'll know what I'm saying when you close the charge door next time.

 

[Sheepish Lord]

Do you think weather temp changes/fluctuations will affect the fit and longevity?

 

[diesel_dave]

Do you think weather temp changes/fluctuations will affect the fit and longevity?

The TPU itself is very durable and abrasion resistant. Extreme cold is my concern. It might make it very stiff and not seal very well. I guess I can toss it in the freezer for a while and run it over to my Jeep and see how does.

 

[Viajero]

Would it be possible to have the shroud go around the outside instead?

That sounds like how the GC does it. It has been zero effort so far.

I should point out that prior to this I drove a C-Max PHEV. It didn't have any kind of rubber plug or seal under the charge port door. In 10 years of driving it I never noticed any dirt or corrosion on the charge plug, nor did I have any trouble charging. Of course I wasn't mud bogging or doing any hard core Jeep stuff in that, but I did drive it on dirt roads and in all kinds of weather without any problem.

 

[diesel_dave]

My Tesla didn't have any kind of cover under the door either. It's honestly probably not necessary unless you are going mud bogging.

 

[Sheepish Lord]

Probably just another way Jeep wants you to think “rugged” when using the vehicle. They need to pull the trigger like Bronco did and make a marine interior you can just hose out.

 

[hellrazor]

Probably just another way Jeep wants you to think “rugged” when using the vehicle. They need to pull the trigger like Bronco did and make a marine interior you can just hose out.

It already is an interior you can just hose out.

 

[Sheepish Lord]

It already is an interior you can just hose out.

Not really. For starters, the floor still has carpet and the seats are still cloth or leather in a Wrangler. The Bronco Badlands doesn’t. Don’t want to hijack this thread but there’s differences.

 

[ttturner68]

TPU is pretty soft yes. Not quite rubber, but close. I have a new design printing that doesn't have that flange at all. It just sort of wedges into the gap between the inner charge port and the outter "shell" and looks more like this:

View attachment 9700

That's just a portion of the whole thing to get the dimensions right. This particular version's wall thickness was too thin so it didnt seal very tightly. A thicker one is printing now. Once I get that dialed in, I'll add the body that will allow it to stick to the door with 3M tape.

I thought I liked the flange style more, but after messing with it, I can see why it won't work well. The issue is when you close to door to latch it, it presses in like .25" and then goes back flush. That presents a problem with a flange type seal because it would need to deform enough to allow the door to close but then also still make a good seal when the door is flush. Probably didn't describe that well, but you'll know what I'm saying when you close the charge door next time.

Have you tried Nijaflex yet. Almost too rubbery, you have to have close feed head, and slow the speed.

 

[diesel_dave]

Have you tried Nijaflex yet. Almost too rubbery, you have to have close feed head, and slow the speed.

I played with it years ago and it was pretty cool. Never bought more because it's pretty $$$. My Prusa MK3 can do it no problem. Just have to go really slow.

 

[ttturner68]

I played with it years ago and it was pretty cool. Never bought more because it's pretty $$$. My Prusa MK3 can do it no problem. Just have to go really slow.

I had Makerbot R2 for over a 10 years, although I don't think anything was left original but the case and rails. Had chinese model for year it caught fire I liked it while I had it now I have large format resin printer... I am not going back, it is messy but lightening fast. I haven't tried any of the rubber soft durometer resin yet, as they are expensive. I your going sell something that the way to go because of the quality and speed.