So I noticed on the mouser page they had a link to a CAD step file for the 40 pin bulkhead receptacle. Here’s a prototype of a 3D printable version of the plug that might come in handy for some. I modified and simplified the step file mouser had provided, so it’s close to the right dimensions but I haven’t yet accounted for tolerances. The idea is to push the pins through the holes and epoxy them in place on the back side once everything is wired.
Above image still has all the holes but I decided to plug unused ones:
After I check the tolerances I’ll post the step and stl files here. Any way we could get the forum to allow stl and stp files to be posted?