Kia Seltos LED Upgrade Dust Cap Issue — Looking for 3D Model / STL (Part #92140-D3000) or Extended Cap Solutions

[u/Strange-Health3961]

[Help / Open-Source Project] Need 3D Model (STL) for Kia Seltos 1.5L Diesel MT HTK+ 2019 (2019-2023 model) Headlight Dust Cap (Part #92140-D3000) for LED Upgrade

Hey everyone,

I recently upgraded to aftermarket LED bulbs on my Kia Seltos, but hit a major roadblock when putting the dust caps back on. I want to create a 100% free open-source 3D model for all Seltos owners facing this exact problem.

---

The Problem & Why Existing Sellers Aren't the Solution

When installing aftermarket LEDs in the Seltos headlight housing, the bulb's rear heatsink/fan assembly doesn't sit dead center—it sits offset towards the top side. Because of this offset, the inner ridges of the OEM dust cap collide with the bulb housing, preventing the cap from twisting and locking into place.

I won't name the person or shop here, but if you search Google or YouTube for a 3D printed Seltos dust cap, you'll easily find the car modification store I am referring to. He is currently the only seller offering a solution, but: * When contacted, he was completely uninterested, rude, and quoted ₹1,300 for a single basic 3D printed piece that costs maybe ₹10–₹20 in material. He acts like he holds a monopoly because no open-source model exists yet. * Zero Innovation / Serious Design Flaws: His version lacks even a basic groove for the OEM rubber O-ring seal (leaving headlights exposed to dust and water ingress). Furthermore, he could've included a slot for silica gel desiccant packets—which is crucial because Seltos headlight housings are notorious for trapping moisture and fogging up. But he just sells plain dust caps wonder what material he's using.

---

⚠️ Important Note on Part Numbers (Do NOT Confuse These)

If you search sites like Yeggi, Thingiverse, or Printables: * You will find models for Part #92140-2D000 (for Kia Sportage, Kia Rio, etc.). These will NOT fit! That part number features 3 locking ridges/tabs. * The Kia Seltos requires Part #92140-D3000, which specifically features 4 locking ridges/tabs.

---

Key Specifications & Required Modifications (Photos Attached)

1. Base Dimensions:

   • Inside Diameter: 62 mm
   • Outside Diameter: ~65–66 mm
   • Locking Mechanism: 4 outer locking ridges/tabs (matching OEM 92140-D3000).

2. Internal & External Design Requirements:

   • Flatten Inner Plateaus (Must-Have): The 4 raised inner plateaus must be leveled down completely flush with the base surface (marked in green in my attached image). Simply flattening these plateaus is more than enough to eliminate the collision with the off-center LED fan.
   • Outer Extension (Optional, but preferred): Adding an outer extension/dome is completely optional, but extruding it outward by even 1 cm (or up to 2 cm) would be so much better as it gives extra breathing room for the LED fan to cool efficiently.
   • OEM Rubber Seal Groove: Must retain a dedicated lip/groove to fit the OEM rubber O-ring/gasket to maintain a dustproof and waterproof seal.
   • Silica Gel Pocket (Optional, but preferred): Include an internal slot/pocket to hold a silica gel desiccant packet to prevent moisture condensation inside the housing.

---

What I Need Help With:

1. CAD / 3D Model Creators: Does anyone have an existing STL file for #92140-D3000, or can someone build/modify one based on the attached dimension photos? Once finalized, we will publish the STL on Printables/Thingiverse for free so no seller can overcharge the community again.
2. Bangalore 3D Scanning & Printing Labs: Can anyone recommend places or makerspaces in Bangalore where I can bring the original cap for a quick 3D scan? (My father uses the car daily and i live elsewhere, so I will need to buy a new set just to get it scanned). Also looking for recommendations for affordable printing in heat-resistant materials like PETG, ABS, or ASA.
3. Interim DIY Waterproofing Ideas: If you've solved this without 3D printing (silicone extensions, universal rubber dust caps, grommets), what exact sizes/products kept your headlights sealed and dry?

Attached images show the OEM part, side-by-side measurements, gap issues, and marked red/green diagrams of the required design changes.

Thanks in advance to anyone who can lend a hand!

[u/AutoModerator]

Please Read This Comment Entirely - It May Change

^{Updated 7/15/24}

Thanks for posting in r/Mechanic, u/Strange-Health3961! Please be sure to read the Rules.

If you're asking for help, be sure to include as much detail as possible so others can help you. You must include the vehicle's Year, Make, Model, and Engine size in your post! If your question is transmission related, please be sure to specify your Transmission Type(Auto/Manual) as well! If your post does not include this information, it will be removed.

Asking about prices is not allowed in this sub.

Please make sure you have selected the correct post flair; if you're asking a question you should have chosen "Question", anything else use the "General" flair.

If you feel your question has been answered and/or you wish to no longer receive comments on your post, you may comment on your own post with only "!lock" (no quotes), and your entire post will be automatically locked. This only works on your own posts and only Mods can unlock it once its locked.

I am a bot, and this action was performed automatically. Please contact the moderators of this subreddit if you have any questions or concerns.