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// 08
RefIE-008
ClientMK ULTRA
Year2024
Scale1:1
[Reverse Engineering][Automotive][CAD][3D Print]

Reverse-engineered Jeep Wrangler side step

A broken Jeep Wrangler side step pad rebuilt from a single worn sample, without any manufacturer files. Measurements, tread pattern vectorised in Adobe Illustrator, 3D model in Shapr3D, FDM printing. The part was fitted onto the vehicle's original step bar.

The finished step after FDM printing, with the tread pattern reproduced.IE-008 · FIG.01 · The finished step after FDM printing, with the tread pattern reproduced.

Problem

The original Jeep Wrangler side step pad had cracked, and an OEM replacement is hard to source and expensive. Only the worn, damaged sample survived. The geometry, tread pattern and mounting points had to be reproduced 1:1 so the new part would fit the existing step bar.

Outcome

A working replacement part recreated from a single damaged sample, without any manufacturer files. Tread pattern and mounting points reproduced 1:1. The part was fitted onto the Jeep's original step bar.

  1. 01Measuring and analysing the broken part: outline, wall thicknesses, the rib layout and mounting points underneath.
  2. 02Vectorising the tread pattern in Adobe Illustrator and rebuilding the solid in Shapr3D, keeping the original mounting points.
  3. 03FDM printing on our own printer farm. The tread pattern provides the step's grip.
  4. 04Fitting onto the vehicle's original step bar and checking the fit.

Specifications

IE-008
Vehicle
Jeep Wrangler
Part
Side step pad (sill trim)
Method
Reverse engineering
CAD
Shapr3D + Illustrator
Production
FDM printing
Fit
On the original step bar
Underside of the original part: ribs and mounting points to reproduce.
FIG.02Underside of the original part: ribs and mounting points to reproduce.
The tread pattern vectorised in Adobe Illustrator next to the printed part.
FIG.03The tread pattern vectorised in Adobe Illustrator next to the printed part.
The worn original: the starting point for measurements and rebuilding the geometry.
FIG.04The worn original: the starting point for measurements and rebuilding the geometry.
The part fitted onto the Jeep Wrangler's original step bar.
FIG.05The part fitted onto the Jeep Wrangler's original step bar.
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