I have to redo part of the model since I had some errors in it. Doesn’t take long, but I’ll make some adjustments. For the notches, I’ll make sure there is enough material, and it will hook further back, not just behind the face. I can’t make it too thick at the face since you would not be able to insert a clip with a 90 degree bend in it.
For the face I have a slight curve top to bottom. Left to right it is tapered but I don’t have a curve…yet. I’ll see how it looks. In the end, the final piece will likely need to be sanded and painted flat black to match the trim material; the ABS plastic naturally will have some shine to it, which will still out too much. I’ll see about other processes that might be able to do a better OEM look, but very likely some minor work will need to be done after printing.
Sounds like your plan for the paper clip tool is on the right track 
The curve is very minor, nearly impossible to see. I had to hold a straight edge to it and hold it up to the light:
I redid the model, So I’ll try to print one tomorrow. The face curvature I can adjust if needed based on the fit of this one.
For the removal process, since the backside of the plug will not sit completely flat on the back of the bumper hole due to the adhesive (like 3M double sided tape), the idea is you rotate the paper clips into the notches and slide them to the back. Once you hit the back, you turn the clip 90 degrees so that the bent part of the clip sits behind the plug. Then it is a matter of just pulling it forward firmly but gently. I’ll post a pic of it later. I wanted to leave a raised area on the back side for the paperclip to slide into, but it means the 3D printer would need to bridge those areas; the plug is printed sitting on its back. I also can’t have any flat areas that require bridging as the printer works up through each layer, that is why you see 30 degree slopes on the bottom and side notches.
I’m considering a 3M dense foam tape, maybe 0.5mm thick or something like that. So it will be strong, and since it is dense it will not have a spongy feel if you push on the plug.
I’ll post pics when it is done.
![2016.04.29-01.07.03-[3D].jpg](https://forum.g2ic.com/uploads/default/original/2X/3/3e21b07713d75a83acda824255739962c3671100.jpeg)
![2016.04.29-01.06.37-[3D].jpg](https://forum.g2ic.com/uploads/default/original/2X/6/602d54675142213cfa69797afd4988b2adf02b1c.jpeg)
Lookin’ good! That design idea for removal sounds perfect. As for tape, the best stuff I’ve found is 3M - the grey stuff with red backing. I’m not sure if there are actually different versions of this stuff or if it’s just packaged for different applications. I’ve been using it for over a decade and at one point found out that it’s the same stuff most OEM’s use for molding attachment from the factory (even Honda). It’s much stronger than the white foam stuff and much easier to remove. You probably don’t need much at all though otherwise it might not be able to be removed.
Printing status?
Printing in abs sucks! I did one on Monday. It started OK but didn’t finish well. It was good enough to try some test fitting. But my bumper hole is so messed up it won’t fit properly. I’ve been on the hunt to buy a bumper locally. It sucks I can get a new 91 bumper for 30$, but not the 93. They are more expensive and harder to find. But I saw a suggestion to just heat up the bumper and reshape the hole. That is what I’ll do. And when I print another I’ll do the passenger side one since that hole is not damaged.
i would be in for this, i have a 91 with 92-93 bumper. will these come painted or require painting after purchase?
Well this started off as a small thing that I wanted to get feedback. I considered waiting until I was done to prevent creating high expectations for something. But at the same time I wanted to share the idea and the experience of making it.
I’m fortunate enough to have the tools to make some prototypes, but it is at work during off times. So progress is slow (and now made more difficult since my bumper holes are miss-shaped; test fitting is a bit more challenging at the moment). If I ever sell something the price will be based on how much work is needed by the end user. At this point I don’t know. I foresee them needing at least flat paint. Light sanding may depend on the final printing process that is used. I think the best results will work for those who want to color match, since matching the paint will b easy. For the un-painted bumper, you’d need to match the flat-black paint with the trim.
What other options are there besides ABS? I’m wondering if this is something worth investing in from the club’s point of view (i.e. buy our own 3D printer). If there are enough tiny parts that could be printed for our model, perhaps this is a worthwhile investment given that hardly anyone would make parts for our cars anymore.
There’s other options but just not for the one off on my printer. For volume there is one or two other options, I just don’t have the names of the types right now.
I’ve been busy at work setting up a new lab, and just getting the Integra on the road, so not much work on it lately.
Bump.
How’s progress? I know its a side project so no rush, just wondering.
Bringing this back. I plan to set up a 3D printer to print out stuff for us within a few months once I’m settled.
Can’t wait