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Enlarging the wheel cover holes?
Is it possible for a metal shop to enlarge the access port holes on my dually chrome wheel covers?

This would allow me a better angle for air filling. Valve extenders won't work with my built in TPMS.
2021 Mid Bath
Re: Enlarging the wheel cover holes?
Reply #1 –
If you don't like access provided by the stock wheel covers, you can:

(1) have the holes enlarge (not a request most shops see very often, but not hard to do)
(2) Remove the wheel covers and just roll without them (Andy, I, and probably others have done this)
(3) Switch to more attractive rims like the Alcoa aluminum wheels (Ford E350 & Ford E450 | 16" Alcoa Wheel Package – Buy Truck Wheels)

There are probably some other creative options out there, but number 2 works for me. 

Rich
2003 MB
Re: Enlarging the wheel cover holes?
Reply #2 –
Ted,

I can understand how you’d prefer to utilize the OEM TPMS. Have you explored purchasing TPMS sensors compatible with the FORD onboard TPMS electronics?  I once bought dedicated “Winter” wheels for my wife’s car and TireRack.com preinstalled sensors compatible with her Porsche’s onboard TPMS.

W
Warren
2019 MB “Dream Catcher”
Jeep Wrangler JL
Re: Enlarging the wheel cover holes?
Reply #3 –

Hello Ted.   Why can’t valve stem extenders work? 
Amazon.com: 6 Inch Dually Valve Stem Extenders,Set of 2Pcs,Heavey Duty,150mm...

It seems that they’d simply screw onto the existing valve stems.   Darn if I know!

As an Amazon Associate Lazy Daze Owners' Group earns from qualifying purchases.
Re: Enlarging the wheel cover holes?
Reply #4 –
Enlarging the existing wheel cover holes is a fairly simple task. I’ve done my from right cover.

Using a Dremel and a Dremel cutting disk you can make quick work out of it. Using a sharpie (small tipped but not necessarily the finest) draw the outline of the whole needed to fit the fill valve.

Watch your eyes due to metal being removed. Starting on the inside of your drawn out perimeter, slowly grind the metal away. Hold the Dremel firmly to avoid skipping across the metal.

The metal cover is fairly soft and removes easily. Remember, once you’ve removed the metal you can’t put it back. Just work your way to the inside edge of your outline.

It’s easy but I can understand if people avoid the process. Use the cutting wheel to finesse the metal away. Once you’ve gotten the opening you want (the cover is folded over itself so you’ll need to cut away the back side of the cover also) you can use a small Dremel bit to remove burrs and sharp edges.

It’s a simple project but requires a good grip, slow methodical movements and a keen eye. I’ve done it twice to the same cover position. Once on the OEM cover and again on its replacement that I installed after crushing the first cover.

Take your time. Careful with your eyes as metal shards can really cause an issue. If the Dremel isn’t for you, a good rat tail file could work as well. Less chance of flying bits of metal.

Good luck.

Kent

NOTE: I’ve never had an issue with the dually cover only the front cover to make room for my TPMS sensor.
2015 27' RB "MissB.Haven"
Re: Enlarging the wheel cover holes?
Reply #5 –
Quote from: Kent Heckethorn  - 
Enlarging the existing wheel cover holes is a fairly simple task. I’ve done my from right cover.
Using a Dremel and a Dremel cutting disk you can make quick work out of it. Using a sharpie (small tipped but not necessarily the finest) draw the outline of the whole needed to fit the fill valve.

I did the same to our LD's wheel covers, the holes didn't line up correctly to use the TPMS sensors.
I used a die grinder with a carbide cutter but a Dremel should work fine too, I would use the Dremel sanding drum attachment, along with a pack of spare sanding drum refills.
I find the drum sanders to be more controllable and less aggressive than the cutting discs.
https://www.homedepot.com/p/Dremel-EZ-Drum-1-2-in-Rotary-Tool-Mandrel-for-Sanding-Bands-for-sanding-bands-408-432-445-EZ407SA/203077220

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Enlarging the wheel cover holes?
Reply #6 –
Quote from: WhiteElk  - 
I can understand how you’d prefer to utilize the OEM TPMS. Have you explored purchasing TPMS sensors compatible with the FORD onboard TPMS electronics?  I once bought dedicated “Winter” wheels for my wife’s car and TireRack.com preinstalled sensors compatible with her Porsche’s onboard TPMS.

I don't think it's a TPMS compatibility issue. Extended stems are intended to be replacements for the existing short stems, for use without OEM TPMS sensors. No one I know of makes a special extended stem that would attach to the OEM TPMS sensor used in the new E450.
TPMS sensors are available with steel stems, instead of rubber, and could use custom bent stem extensions.

In a previous thread, I suggested that adding a second hole in the rim is one way of accommodating both the OEM TPMS sensor and conventional extended stems.
At this point in time, having the ability to monitor 10 TPMS sensors requires removing the OEM TPMS sensors, installing extended stems, and running an aftermarket, 10-channel monitor and ten outboard sensors.
A makeshift system using the OEM  sensors, for the coach, and aftermarket TPMS sensors, for the toad, could be done using old-school extension hoses, the type that is prone to leaks if not tightened regularly. It wouldn't be pretty but could be made to work.
https://www.etrailer.com/Tire-Inflator/Wheel-Masters/WM8001-135.html

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Enlarging the wheel cover holes?
Reply #7 –
Quote from: Ed & Margee  - 
Hello Ted.   Why can’t valve stem extenders work? 
Amazon.com: 6 Inch Dually Valve Stem Extenders,Set of 2Pcs,Heavey Duty,150mm...

It seems that they’d simply screw onto the existing valve stems.   Darn if I know!
Everything I'm reading indicates the extenders aren't compatible with the new stock TPMSystem.
As an Amazon Associate Lazy Daze Owners' Group earns from qualifying purchases.
2021 Mid Bath
Re: Enlarging the wheel cover holes?
Reply #8 –

Hi Ted. If you can fill the tire with a standard air chuck, you can attach a solid extension.  Most people seem to have problems with the flexible hoses. There are many sizes, shapes and other solid extensions available.   Amazon.com: 6-Pack Tire Valve Stem Extensions, Mellbree 45 Degree 90 Degree...
   A short one with the filler end anchored by a hard rubber grommet should work. I wouldn't stick an 8" metal pipe on a tire valve without something else to keep it steady.  You could use a hole drilled in the tire cover to keep it in place. Use thread sealer on the threaded together parts. 
    A towed vehicle could have a non Ford TPMS. (such as a TST 507)  with a remote amplifier in the fake tire cover, and the readout on the dash just for the 'towed'. You could take that readout with you when the 'towed' was separated and on its own. RonB

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RonB (Bostick) living in San Diego
Original owner of "Bluebelle" a '99 TKB
Re: Enlarging the wheel cover holes?
Reply #9 –
Quote from: tedeboy  - 
Everything I'm reading indicates the extenders aren't compatible with the new stock TPMSystem.

With duals, one stem on each side is pointed toward the center of the vehicle, not toward the outside, normally requiring the use of a bent stem extender or in the case of the new E450, a double-headed air chuck.
Milton S-693-12 1/4" FNPT Extended Reach Dual Head Air Chuck
Amazon.com : Milton S-693-12 1/4" FNPT Extended Reach Dual Head Air Chuck

Until the aftermarket comes up with an alternative solution, Ted needs to use the conventional style of dual air chuck for the rear tires.
He can add a four-channel TPMS for a toad, if he pulls one.

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: Enlarging the wheel cover holes?
Reply #10 –
TED,  In the distance past I too have used the flexible hose extenders which were quite unreliable as they could come loose by flexing and I even had one come apart at the crimped on ends. I do not recommend using those.
I have used the TST monitoring system for at least the last 8 years with no problems and am very glad to have them especially for the toad. I prefer the button style sensor on the Borg extended valve stems which makes it easy to add/adjust the air in the tires. I also mounted the TST signal repeater in the back window of our 2021 rear bath.
I had checked with a Ford shop about what problems I would have with the engine computer and dash readout if I removed the Ford pressure sensors (photo) and they said the only thing would be a tire pressure warning in the dash display at engine startup which could be deleted with one push of the "OK" button on the steering wheel. Simple as that! This would have no other effect on the computers function.
So that is what we do each time we start the engine. I find that easier than having to continue to use the Ford valve stems which will have to be replaced when the batteries drain.  It is very easy to replace the TST sensor batteries.
I did have to trim the rear stainless wheel cover openings for the sensors to clear. (photo) I used left/right aircraft tin shears to do the trimming and the Dremel to smooth the cut edges. Just took a few minutes. The front wheel covers needed no adjustment to clear the Borg stems and TST sensors. (photo)
We just completed a 7500+ mile round trip from Florida to California (and many places in between) during the sweltering western heat and we were easily able to keep close watch on all ten tire parameters of pressure and heat.  All went well.
 
2026 Coach House 27' "Casa Azul"
2010 RB "Monty"  &  2021 RB "Villa Verde"
2004 Born Free 26'
1998 Beaver Patriot 33'
1992 Barth Breakaway 28'
1982 Fleetwood Jamboree 23
Re: Enlarging the wheel cover holes?
Reply #11 –
Quote from: Larry W  - 
With duals, one stem on each side is pointed toward the center of the vehicle, not toward the outside, normally requiring the use of a bent stem extender or in the case of the new E450, a double-headed air chuck.
Milton S-693-12 1/4" FNPT Extended Reach Dual Head Air Chuck
Amazon.com : Milton S-693-12 1/4" FNPT Extended Reach Dual Head Air Chuck

Until the aftermarket comes up with an alternative solution, Ted needs to use the conventional style of dual air chuck for the rear tires.
He can add a four-channel TPMS for a toad, if he pulls one.

Larry

I do have that Milton Extended Reach.

Not having to remove the wheel covers would be very convenient. I'm going to contact some metal shops locally about enlarging the wheel cover holes.

ON EDIT.
Rather than enlarging that hole I'm wondering if there is a extended reach adapter that has less of an angle than mine? That would work I think.
2021 Mid Bath
Re: Enlarging the wheel cover holes?
Reply #13 –
That Jaco looks like a good idea except you have to press a lever to get it to release.  I can't get my hand into the wheel that far.

Linda B
Green 2021 RB
2022 Ford Maverick toad
Re: Enlarging the wheel cover holes?
Reply #14 –
Quote from: Linda B  - 
That Jaco looks like a good idea except you have to press a lever to get it to release.  I can't get my hand into the wheel that far.



I'll look into that before purchasing.
Thanks
2021 Mid Bath
 
Re: Enlarging the wheel cover holes?
Reply #15 –
Quote from: Ed & Margee  - 
Hello Ted.   Why can’t valve stem extenders work? 
Amazon.com: 6 Inch Dually Valve Stem Extenders,Set of 2Pcs,Heavey Duty,150mm...

It seems that they’d simply screw onto the existing valve stems.   Darn if I know!

I put metal extenders on for my EEZ TPMS system. Works great.
As an Amazon Associate Lazy Daze Owners' Group earns from qualifying purchases.
2004 31' Twin Bed