Replacement Cooler Bung (Stopper or Cap)

prusaprinters

<p>This is a replacement bung for a cooler's bunghole, i.e., a stopper or cap for the water drain hole on the side of a cooler. My old bung disintegrated after years of faithful service stopping liquids from coming out of the cooler's bunghole. I stopped it up with chewing gum until I could get home and make this replacement part.</p><p>You'll need TPU for your bunghole. The inner diameter is slightly smaller than the bung size for a water tight fit which requires flexible filament. I printed the section that slides over the bunghole at 0% infill to allow the TPU to flex over the bunghole. See the last photo and printer settings below for details on how to do this right. It also has a chamfer on the inner edge that makes it easy to slide the bung on the bunghole.</p><p>Note: This bung is sized for my particular make and model of cooler, but should work well on most. It may need to be scaled up or down in the X/Y axis for your particular cooler. My Igloo CoolRoller's bunghole has an outer diameter is 17.6 mm; the new bung's inner diameter is 16.5 mm.</p><p>Important print settings (see 3MF file for details):</p><ul><li>Nozzle size = 0.4</li><li>Layer height = 0.15</li><li>Perimeters = 2</li><li>100% infill up to the top of the finger grip (0 to 2.45 mm)</li><li>Above 2.45mm:<ul><li>0% infill</li><li>Disable Ensure Vertical Shell Thickness</li><li>Disable Fill Gaps</li><li>This should leave the upper portion of the bung completely void of any infill other than the perimeters which will allow it to flex into a tight seal.</li><li>If you need to stiffen the print, add additional perimeters and/or gyroid infill, but the point is to have it flexible enough to seal against the water pressure from inside the cooler.</li></ul></li></ul><p>Made in FreeCAD in about 5 minutes; files are provided as well as the STL for remixing. I was tempted to add an imprint of photo of a certain cartoon character from the early 90's on the bottom; let me know if you do that and my cooler's bung will be upgraded. Printed on a Prusa MK3S with Overture TPU using Prusa Slicer.</p><p>&nbsp;</p><p>…Why is there a teenager in my room mumbling something about the Great Cornholio?</p>