My attempt at stopping bed cap water leaks - 3D printed

[CaptAngry]

In my never ending obsession of using the 3D printer to fix problems (sometimes even if they don't need a fix!) I modeled up my own attempt at stopping water leaks in the six bed cap holes. I was inspired by purdyd's TPU attempt: https://www.ranger6g.com/forum/threads/a-thought-on-stopping-stake-pocket-leaks.27352/

Printed in ASA and using M5x6 heatset inserts. I put a tiny bead of black RTV gasket maker under each before screwing down with stainless fender washers and M5x10 hardware. The part that sticks above the rail is 1mm thick

Of course my tonneau is not here yet so I can't really test them until then. But I'm pretty sure they will stop the leaks

Note: I have a 2026 so the plastic is lower and gap between plastic and metal is less than 2024/2025

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[Loudpa]

Interested in as I also have a 2026 and a 3D printer.
Was thinking of just applying waterproof tape as it's very thin.

Will you share the STL?

 

[CaptAngry]

Here ya go:

https://www.printables.com/model/1685920-2026-ford-ranger-bed-cap-plugs

 

[Loudpa]

Here ya go:

https://www.printables.com/model/1685920-2026-ford-ranger-bed-cap-plugs

Thanks
Wonder if PETG would work also have a ton of it in black.

 

[CaptAngry]

You could try it. I hate PETG with a passion so I only keep a minimal amount for certain projects

 

[Todd]

In my never ending obsession of using the 3D printer to fix problems (sometimes even if they don't need a fix!) I modeled up my own attempt at stopping water leaks in the six bed cap holes. I was inspired by purdyd's TPU attempt: https://www.ranger6g.com/forum/threads/a-thought-on-stopping-stake-pocket-leaks.27352/

Printed in ASA and using M5x6 heatset inserts. I put a tiny bead of black RTV gasket maker under each before screwing down with stainless fender washers and M5x10 hardware. The part that sticks above the rail is 1mm thick

Of course my tonneau is not here yet so I can't really test them until then. But I'm pretty sure they will stop the leaks

Note: I have a 2026 so the plastic is lower and gap between plastic and metal is less than 2024/2025

That looks like it should work quite well, especially with the added ability to draw it snug against the rail with the added hardware. Do you think this would work on my 2025 Ranger?

 

[CaptAngry]

I noticed a downside to these covers that essentially fix the rail to the body: Warping

It is only 75°F here today and in the sun, the bed rail on both sides is warping upward. I assume because the plugs are not allowing expansion of the plastic. Not sure how a tonneau bolted down would impact this or not

I might see if I can figure out a clip-on design, or something that only clamps to the plastic itself (and using the holes in the body to tighten screws)

 

[superj]

dang. who would have thought that would happen?

 

[Sauce]

Wouldn't a bed rack that bolts into the stake pockets have the same issue? I haven't seen anyone with a bed rack experiencing the same warping. Is it an issue in those use cases? If not, why is that any different?

 

[purdyd]

I noticed a downside to these covers that essentially fix the rail to the body: Warping

It is only 75°F here today and in the sun, the bed rail on both sides is warping upward. I assume because the plugs are not allowing expansion of the plastic. Not sure how a tonneau bolted down would impact this or not

I might see if I can figure out a clip-on design, or something that only clamps to the plastic itself (and using the holes in the body to tighten screws)

I have the ford one on both of my trucks. It is a little brittle compared to linex. I have a couple of chips and gouges in the bed-liner that doesn’t usually happen with the line-x.​

Yeah I’m thinking the same thing. Someday….

 

[Todd]

Any further progress in coming up with an effective seal?

 

[CaptAngry]

I am still waiting on my tonneau so I can't really tell if this seals things up or not. They seem to be holding up. I loosened the bolts a bit and the warping seems to have minimized.

 

[SmokingGhost]

In my never ending obsession of using the 3D printer to fix problems (sometimes even if they don't need a fix!) I modeled up my own attempt at stopping water leaks in the six bed cap holes. I was inspired by purdyd's TPU attempt: https://www.ranger6g.com/forum/threads/a-thought-on-stopping-stake-pocket-leaks.27352/

Printed in ASA and using M5x6 heatset inserts. I put a tiny bead of black RTV gasket maker under each before screwing down with stainless fender washers and M5x10 hardware. The part that sticks above the rail is 1mm thick

Of course my tonneau is not here yet so I can't really test them until then. But I'm pretty sure they will stop the leaks

Note: I have a 2026 so the plastic is lower and gap between plastic and metal is less than 2024/2025

I did the same thing with mine and 3D printed covers in ASA-CF. Made some changes to mine with a TPU gasket at the recommendation of purdyd that seems to have worked really well. I also added LockTight to the screws as they kept loosening from driving over time.

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