Ford Mustang Mach-E + StealthHitches Dremel Cutting Guide and Covers

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These parts are for putting the "polish" on the installation of a StealthHitches rack receiver on a 2021, 2022, or 2023 Ford Mustang Mach-E. These may work on future year models as well, if Ford doesn't significantly change the design, but only time will tell. This is a three part kit, consisting of a Dremel Cutting guide, and two covers for use with and without the receiver installed. The Dremel Cutting Guide can be printed in PLA or PETG or any sufficiently hard plastic. The two versions of the cover need to be printed in TPU or other flexible material with a Shore Hardness rating of 95A (or close too it). The covers need to be flexible enough for the retaining flanges to be maneuvered through the cut in the bumper cover. TPU 95A will also allow the cover to conform to the contour of the bumper cover. You'll note that there are actually four versions of the covers -- the "with brim" versions are the ones that I actually used with layer-height 0.25, because I had trouble with bed-adhesion. The covers are too big to fit my 300x300 bed when using my slicer's brim feature. Also, by making my own in-built brim, I could better control the handling at the corners to make for a cleaner removal of the brim. For background, more pictures, and discussion, please see the post over here: https://www.macheforum.com/site/threads/stealthhitches-diy-3d-printed-solution-dremel-cutting-guide-and-covers.25995/ NOTE: These parts are offered for NON-COMMERCIAL USE ONLY! If you can't print these yourself and someone else does it for you, it's fine for them to recover their time and materials, but they should not be charging a penny more. Folks have violated this in the past and if it keeps happening I'll simply stop sharing my designs. PERIOD. The specific StealthHitches model is over here (rack-only): https://stealthhitches.com/products/ford-hitch-shr11001 NOTE: I did not buy nor design this part for the towing kit and I expect there would need to be accommodations for the chain anchor points. Send me a comment (preferably on the MachEForum.com) if you have the towing kit and if there is enough interest, I may see what I can do to accommodate. General Installation instructions can be found at the above Stealthhitches.com link. The only thing that did not apply on my 2023 Ford Mustang Mach-E was that I did not need to move the wiring harness mentioned in step 4. Ford had already taken better care to position that harness out of the way on my 2023 model year MME. Beyond the StealthHitches instructions, when it comes time to use the Dremel you should have already removed the screws along the front edge of the rear-bumper cover. That will allow the large flexible diffuser to move more freely, which is important so that the two bolts re-inserted through the 3D printed Dremel Cutting Guide will "find the center" of the holes in the rear bumper cover. That will allow for more precise positioning of the cutout in the bumper cover. Pro-Tip: Practice all of the Dremel cutting steps on a piece of plexiglass, before going near your MME! If you happen to allow the blade to stray into the 3D printed Cutting Guide, then be sure to print a new part before you go forward with the cut on your actual MME. Using the 3D printed Dremel Cutting Guide: 1) The ~28mm offset on the Dremel Cutting Guide, requires the use of a Dremel 565 Multipurpose Cutting Kit / Router Attachment, and cutting blade. 2) Before mounting the Dremel cutting guide use electrical tape to cover the "sharp" edges of the 3D printed part so that the vibration of the Dremel doesn't allow the 3D printed plastic to scratch the bumper cover. 3) Use a piece of packing tape along the rear edge (nearest) of the Dremel Cutting Guide to secure it to the bumper cover. This is to help keep the guide securely in place while cutting. When practicing on a piece of plexiglass, just use the packing tape all the way around the 3D printed Dremel cutting guide, to secure it to the plexiglass. 4) For the actual cut, make a pilot hole using a 7/64ths drill bit close to one edge of the 3D printed Dremel cutting guide. I drilled the pilot hole along the long edge of the guide, near the rear driver's side corner of the guide, about an inch to the right of the corner. 5) Use a brand new Dremel blade with your Dremel on its highest speed. Insert the bit into the 7/64ths pilot hole and THEN turn on the Dremel. Hold the Dremel stationary until it comes up to speed. 6) Cut very slowly in a clockwise direction around the outer frame/platform of the 3D printed Dremel cutting guide. Let the blade do the work, don't use pressure. If the blade stops moving, just back it up a few millimeters and advance it gently to coax it along. 7) Use a small palm-plane to smooth out the widest edges of the cut. Use a box cutter with a brand new blade to smooth out any edges where the palm-plane cannot reach. You can also use a file to smooth out the edge, but that leaves it grey / dull, so if you can manage with the palm-plane and box cutter you may achieve a cleaner look. NOTE: It is very important to carefully "sight," from the side, the Dremel's 565 Multipurpose Cutting Kit guard to make sure that you keep it flush at all times with the 3D-printed Dremel Cutting Guide frame/platform. The support for the cutter guard is only on one side, so you have to take care to keep the Dremel's 565 cutter guard flat, so that the bit is kept perpendicular and doesn't stray from the intended line. Positioning the hitch before final torquing: 1) Snug, then losen, the four nuts that hold the hitch to the frame (1/2" bolts). You want the nuts most of the way on, but loose enough to allow you to fine-tune the position of the hitch front/back and left/right. 2) install the "With_Receiver" version of the cover over the round end of the receiver so that the smooth side of the cover faces the floor. 3) Install the receiver into the hitch (through the cover). Do not try to fully install the cover at this time. 4) Using the receiver like a large "handle," you should be able shift the hitch in any horizontal direction to center it left-to-right and front-to-back so that the "With Receiver" cover will fit perfectly centered. 5) Fully install the "With Receiver" cover and fine-tune the position of the hitch so that it is neatly centered within the opening of the cover. I found it necessary to push the hitch as far forward as possible to allow plenty of room for the cover to clear the square receiver-receiver. 6) Fully torque the nuts for the 1/2" bolts that hold the hitch to the frame. 7) Proceed with the rest of the StealthHitches installation instructions. HINT: The covers are most easily installed from one end, starting with the corners and then "warping" the cover to help the flanges get past the edges of the cutout.