Indeed, a “one size fits all” design seems unlikely to fit for everyone. I’ll slap together one that fits my “mostly deburred” 1" ID pipes. Those Amazon ones are expensive and definitely would not fit. I see some on Grainger for 1" EMT but 3D printed ones will be perfect and “almost free.”
I try. Using a brand new deburring blade it shaves off some filings, but as I keep pushing and trying, I still have some bur left. At least I get the sharpness knocked off of it.
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Short of using a dremel tool, I’ve had the same experience.
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Before I got the actual conduit tool I did it with a half round file, takes about 1 minute a side. A deburring tool is not easy to use in steel on an edge that large, but a file guts right through.
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This is what I used, but unfortunately no longer in production…
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Lowes website shows this on sale (clearance) for $10.57, but “in store only.”
https://www.lowes.com/pd/Kobalt-1-8-in-5-8-in-Removal-Tool/1002645156
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So it was marked down even more than this. Got it for only $5.57.
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Did they have any Kobalt routers on clearance as well…? 
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NOTE: Can’t speak for un-reamed 1" EMT, but fit my 1" EMT perfectly. Also, agree not cheap at $1+ each, but free shipping with Prime.
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Ah, I misread them as 1 1/8" ID. Cool!
I definitely spent more than $8 of my time (but fun = free!) but I slapped one together anyway. Seems to work well, f3d model is parameterized if not. It has a small “taper” on the inner rim to “wrap around” the burr part.
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OK, I made this revision of my end caps for 1" EMT, and I’m currently printing to try it out. 11 min print for me.
OK, I printed it, and tested in both “non bur” EMT, and “de-burred / blunted bur” EMT.
It fit snug and removable from the EMT with no bur, and tight and difficult to remove from the EMT that had a bur, but it worked in both.
Download link:
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Sorry, I missed seeing this from you.
Cool! Mine is actually too loose for the factory ends, so will tweak. From zero to two 1" plugs on printables, a win for all!
I like your “ripples”, certainly more forgiving with different diameters.
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Putting this here because I dialogued with Ryan in private message instead of on forum, which hides the help from others.
I printed my dust shoe out of PETG for heat resistance, yet printed my dust skirt out of PLA, which meant they got printed at different times. The skirt would not fit. I thought it might be a design glitch on part size, and sent him a photo. He recommended to print both shoe and skirt at the same time, saying (essentially) the difference in shrink rate between two prints means even the difference between filament types is not the main factor, it’s the different part cool-off periods and different shrinkage.
This may be mentioned in the docs and yet I had not seen it because of much of my print work being during beta phase and early release phase.
So, bottom line is: print both shoe and skirt together, and let them cool down together after the print.
PS: my new set does fit!
Thanks, Ryan!
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@Tokoloshe requested longer bristles from Ryan, and Ryan posted them for him to test:
@Tokoloshe said the test went well. He’s printing extra of the skirt so he can swap between 22 mm and 32 mm just by swapping the skirt. I am doing the same but have to double up since I have two LR4 (small and large).
Posting here to increase visibility and sample size on testing. Will report back.
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That’s been said several times now. 
Somehow I missed it. 
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There are so many nuances it is hard for even me to keep track of them. Really starting to think while the parts are functional they might be designed to too high of a tolerance and making printing harder than it needs to be.
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Where do you see any tolerances that could be eliminated? Actually curious, because everything fits together well and does not wobble or move in any way it shouldn’t. 
The shoe has been problematic for a few users, but that’s about it?