2009 Dodge Challenger Console Door back plate part

This is for a 2009 Challenger RT center console door back plate.  The tab broke off the original and when I went to Mopar for a replacement, it was $302.  They don’t sell just the plate and you have to buy the whole arm-rest, still expensive for the whole thing.  So, I decided to 3D print the plate.  The real issue was with the mating to the handle.  The handle has a little barb on one side at each end that you need to account for. 

The plate can be printed without support.  I have designed in a 1mm thick cover over the hole to help with the bridging and you can easily poke through that with the screw, knife or screwdriver.  The tab piece should be printed on its side (270degrees) and just support the bottom side of tab.  The holes do not need support to print. 

I printed this during trial and error in white PLA to easily see everything.  My friends at work say you should print this in ABS if you live in a high temperature area – I live in Albuquerque, New Mexico and it can get really hot inside a closed car (always use a front window sun deflector).

This part lasted well over ten years before it broke but I decided to print in two pieces with the center screw hole and tab as separate piece.  So, it it ever breaks again, then I only have to print and replace that piece. I include a single piece version if you want to go that way.  If you print the single piece then you will need support for the tab.

Just for fun I placed the Mopar part number on the inside in case anyone has more money than they know what to do with and wants to check out that option.

3 October 2023 update: My grandson said it needed to be a little tighter.  So, I move the lever and hook up 0.75mm so it is now a little “tighter.”  I decided not to delete original files in case for some reason yours is too tight.  New version has 03102023 date in the file names.  Four files: 2 stl files for the “main board” and the “tab and screw” section, and then an stl file for the complete 1-piece back plate and then the STEP file for the 1-piece back plate.  I added the ABS black printed final - it is black even though it looks green.

Filament: Recommend ABS if hot weather is an issue.

Support:

 None needed for Main Board

Tab and Screw section, print on side (270 degrees) and support tab, not hole.

1-Piece back plate, no need for support for screw holes but you will need to support tab.

Brim: 

Recommend no brim for main board or 1-piece.  It has smoother edges with no brim.  Also, with brim it just barely fits on my Bambu 256mm build plate.

Tab and screw, can't hurt to use brim.

Fill: I used 20%.  I don't think there will be much stress, but if you are worried then try 100%.

I used PEI Texture plate to give a pattern on visible surface.

I would live to see a print to know someone actually benefited and didn't have to pay the $302.