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Unfortunately, I can't help support this project monetarily since I have no need without a crew cab truck of my own, but I just want to comment and give support for anybody looking to go out and build their own obsolete parts on these trucks. Having a source other than the junkyard for rebuild projects will make things much easier (though not cheaper).
Are you talking about the Grey piece on the back or the recessed holes on the top for the mounting screws for the door panel?
I was talking about the recessed holes on the back(window lock) side. I made a heck of a mess back there, and I dont think it will hold forever, so I am still interested.
For smaller runs, a 3D printer might be the ticket. I'll see if I can create a really rough part to upload to this site for an estimate, but if we assume they can get the right material, the prices might not be too bad for small volume runs.
Edit: Found a couple minutes at work to do this quick. It's really quick and dirty and a lot more accurate details and features would be needed, but here's a rough what-if scenario.
This is the rough model:
And here's the price list. Obviously it's a rough estimate, but some of the low end pricing seems reasonable assuming the plastics are acceptable.
I think 3D printing would be the best way to go to get a sample or even continue with it for the production of the piece.. Hell people can make guns out of 3D printers...
I like the 3D Printer option, as long as they can use a durable material. Logan the top black piece isn't what breaks, it is the bezel under the black cover, and the screw holes where it attaches to the door. It would be good to get a complete undamaged one to use as a model. I think there is one in my local JY if I remember right, that I never went to look at b/c I settled with my JB weld.
That is the main worry about using a 3d printer is the substrate. As far as the bottom breaking off is the way it is plastic welded to the top plat. All the broken bezels I have seen have always been the top plate.
That's the other option. The bad part is then you have to have it anodized. Or have a matching set for the front. Then it looks like crap. I have a guy I'm going to see tomorrow about machining them out of aluminum