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Discussion Starter #1
Has anyone tried to fit a Challenger filler cap to a Avenger?

I don't have the option to walk into a parts shop and look/measure one, does anyone have access to measure a cap? or is there another option that will work and give the same look?

Pretty sure I can 3D print an interface but need to know if the outside diameter is close enough.
 

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There is a posting on the forum if you do a search. There was a bit of modification involved.
 

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Found it:
 

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Discussion Starter #5
As a back up, I've drawn a "cap" I can 3D print and fix to the original hinge, Will print one when I get back to work but hopefully I can fit a real one.

If anyone wants the .stl file to have a go let me know and I'll email it (can't attach it here)
cap.jpg
 

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Discussion Starter #7
as one does, I've spent last night thinking (more like over thinking) about the cap, even though I hope not to use it I have re-done the 'fake' cap so it should now just stick to an original Avenger flap with out any mods, except swaping the ribber stops for thiner and setting the hinge back a bit.

cap b.jpg
 

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Discussion Starter #8
I know this is getting silly but while prepping the cad drawing for printing I noticed I had made a stupid mistake, I had drawn it flat and the OEM cover is curved, so here is the final rendition that I will print on monday if I get the chance.

I am going to paint and fit this just to see if it works, and the real one I have ordered won't be here for 6 weeks :confused:

cap v3.png
 

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Good luck to you in your "mod", hope it works well for you and your ride! Definitely will give it the "special" look to your Avenger! :)
 

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Discussion Starter #10
So here is the first prototype, trail fit half way through paint prep, hard part was getting the curve to maych but think its there now.
20200507_091131.jpg 20200510_120226.jpg 20200510_120241.jpg
looking at setting the OEM flap back by 2mm without cutting and then its just a case of bonding on the fake filler after the paint is finnished.
 

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Nice custom touch!
 

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Discussion Starter #14
so after fitting it, I scrapped it, the pull slot was to big and I didn't like the center bit.

here is the latest version that I will print next week (working week on/week off) and I have a second flap from the breakers so I dont have to glue it to my original, incase I need to swap it back.
BTW it won't be green, just easier to render in bright colours

CAP7.jpg
 

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Discussion Starter #17
so after two 'prototypes' that I didnt like and 7 redrafts
20200520_160500.jpg
I finaly have a fake filler I like
20200519_160156.jpg
I bonded to a filler flap with 212FC panel bond and left overnight
20200520_111835.jpg 20200520_111755.jpg
And today its been a case paint and paint again. As I had limited time on site this week I went for a courser faster print, that ment a liberal use of filler primer (after adhesion promoter)
20200504_170551.jpg 20200520_113656.jpg 20200520_160204.jpg
Will leave overnight again and then final flatening and a few coats of satin black
By the weekend it should be fitted
 

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Discussion Starter #19
it's on, fitted with added shims and reduced rubber stops to keep it flush, still need to find a way to 'adjust' it up by a few mm but happy over all.
20200521_112212.jpg 20200521_112201.jpg 20200521_112221.jpg 20200521_112229.jpg

I have also uploaded three versions in .3dm and .stl format for anyone to use
Download Fake Filler Files
 

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Nice! Did you remove the existing filler cover or did you attach this new one over top with adhesive?
Thanks for the files!
 
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