Ford F-250 Super Duty Side Step End Caps

This is a replacement end cap for side steps, tube steps, running boards, whatever you choose to call them for Ford F-250 Super Duty trucks. This was modeled from an original Ford part from a 2006 truck with the Ford factory/accessory side steps. See the images for a picture of the step installed on the actual truck.

I don't know what years Ford put these steps on. My best guess would be most of the mid 2000's.

A coworker of mine has this truck and after many years, the spring nut that the screw holding the cap in place into rusted away. This caused the cap to go bouncing down the road never to be seen again. Ford doesn't sell the caps, the steps are discontinued, and every time he found them at a junkyard or ebay, they were gone before he could get there. He asked me if I could remake one. So I made him a full set of 4. You know, because 3D printing for the win.

He let me borrow one of the others that was still on the truck to take measurements. I modeled it in Fusion360, printed some tests so he could test fit, and we arrived at a final model that fits nicely. A side by side comparison of the original part and printed part are provided in the images.

If you are going to actually make this, PETG or other outdoor/extreme weather capable material is a must.
I printed them in Polymaker Fiberon PETG-CF. They came out very nice. The CF inclusion helped to hide layer lines and give a more “professional” look and feel.

This doesn't require supports.

Because I used PETG-CF, I used a .6 nozzle

.18 layer height
3 walls
3 top and bottom layers
15-25% adaptive cubic or gyroid infill


My usual (non-specialty filament) print settings are:

.2 layer height
3 walls
3 top and bottom layers
15-25% adaptive cubic or gyroid infill