Automotive Fuel Door (mount)

I created this for use in my 1982 E350, as the custom nature of mine left the fuel tank inside the cabin. I moved it to in-between the frame rails, and needed somewhere to properly mount a fuel door. This may not be a full door, but is something that will work to get me by, or may be my final build decision. 

I used ASA in 2 colors, white and black, and PETG for support interfaces using a Elegoo Centauri Carbon 2. 

It is designed to be used with 5/8" Flush Mount Fuel Vent, and a 2" Marine fuel filler, both available in a variety of different forms on Amazon. 

The surface bolt holes are designed for a M3 or M4 bolt, but M3s will fit better. The filler neck holes are based around the ones my filler neck came with, closer to M5 or M6, M5 will fit better and is designed to have a nut on the backside. It could be tweaked so you can thread a screw directly in if you made the holes smaller, but I wasn't confident in the ASA's ability to hold onto a screw long term.

The 3mf is what I used on my Elegoo CC2, and the file should be ready to run if you have the filaments loaded. Mine is set for a smooth PEI plate, only because I was trying to get that Carbon Fiber aesthetic on the outer surface. A normal PEI plate may work much better, as mine still had warping issues due to the smooth nature, and lack of adhesive (so I could get the pattern)

NOTE: The below settings were extracted from the profile using AI. The model and process settings were designed by myself.

Printer/Device: Elegoo Centauri Carbon 2 0.4 mm hardened steel nozzle

• Slicer: ElegooSlicer

• G-code flavor: Klipper

Materials / tool mapping

• Filament set in project: ASA, ASA, PETG (all Elegoo profiles)

• Main body (Body3) uses Extruder 1 (Black ASA)

• Recessed 90+ text modifier uses Extruder 3 (White ASA)

• Support interface filament is set to Extruder 4 (PETG interface workflow)

Core print settings

• Layer height: 0.16 mm (first layer 0.20 mm)

• Line width: 0.42 mm

• Walls: 5

• Top layers: 7

• Bottom layers: 6

• Infill: 32% Gyroid

• Seam: Nearest

• Supports: Enabled, Normal(auto), Grid

• Support interface: top layers 5, spacing 0, support speed 30, interface speed 18

• Brim: 18 mm, outer+inner, object gap 0

• Prime tower: Enabled, width 45, brim width 5

• Z-hop: 0.3

Speeds

• Initial layer: 10 mm/s

• Initial layer infill: 12 mm/s

• Outer wall: 36 mm/s

• Inner wall: 54 mm/s

• Sparse infill: 66 mm/s

• Internal solid infill: 60 mm/s

• Top surface: 30 mm/s

• Bridge: 18 mm/s

• Travel: 200 mm/s

• Travel acceleration: 2000 mm/s²

Temps (project arrays, multi-material)

• Nozzle initial: 265 / 265 / 265 / 250 C

• Nozzle: 260 / 265 / 260 / 250 C

• Bed initial (hot plate): 112 / 108 / 112 / 82 C

• Bed: 112 / 103 / 112 / 80 C