I use FreeCAD. I just finished a project today that required a lot of printing.

My wife didn't like opening her F150's tailgate to plug things into the 7.2kw ProPower outlet.

I'm going to dump a bunch of pics then edit to explain them.

I started planning this at the beginning of the year and purchased a replacement power panel so I could take it apart and have it at my desk while I reverse engineered a new cover.

Having a spare also means I can swap it back if there are any warranty claims.

Here is a pic of the outlet box viewed looking up at it from under the bed, just after of the wheel well.


This pick shows the back of the bumper where I decided to mount the L14-30 outlet.


And here is a pic of a guide I printed for my hole saw since the center bit in the hole saw wasn't going into metal and I was afraid of the edge of the hole saw getting a bite of metal and losing control of it and gouging up the bumper.


Here's a pic of the L14-30 outlet. It basically looks OEM when closed.


Here is the backside as installed.


This sleeve goes over the backside of the outlet so none of the terminals are exposed. It also keeps most of the water and dust off the back of the outlet.


Now we start getting into the fun part. I designed a new cover for the outlet box to bring a new wire into the box.


This is an earlier version in white so the details are a bit easier to see.


I made the new box 10mm deeper to accommodate some wago connectors inside. These snap in but are a bit tighter than I like.


This is the 240v 30A receptacle on the circuit board inside the outlet box.


And here is the plug that goes in it. I was able to find that plug on Mouser and built a custom connector to feed the wago connectors since the original connector wire were too short to reach.


This next pic is a bit embarrassing but it shows the new box wired up before I screwed it shut. I really wish I had the wago connectors located differently so I could make the wiring a bit cleaner but this is a 15 hour print and I didn't want to wait another day for a tweak that may still not provide much improvement.


And here is the box installed in the truck. It barely fits through the mounting hole in the bed so there is still lots of room for improvement.

Ok. I did this last weekend while printing the outlet sleeve for the F150. It's a pattern template for a friend who is into leather carving. The cross and flower pattern are typically used for bible covers. The pattern is raised .24mm above the surface of the plate so he can press a light pattern into wet leather so he has something he can follow when carving.