End Caps for Lockrack Cargo Racks

I really like the Lockrack system in general. That said, their default end caps have come loose easily. They also have a few gaps that I don't like so much. So …

There is an end cap matching the original but much deeper for a more secure fit. There is another end cap for that same (left) side that covers the end of the aluminum channel more fully. Additionally, I created caps for the other side (right) where the lock pin is. One mirrors the original, the other mirrors the fuller version for the most clean look.

I printed these in TPU 95A with a 0.6 nozzle at 0.24 layers and random seams. The left side plugs are about 0.3mm larger to ensure a snug fit. Even in TPU, I still used a rubber mallet to force them into place. The right side plugs fit a little more easily. That said depending on your settings you might need to adjust hole/x/y size to get the fit you want. The right side plugs are meant to lock in place, meaning you will need the key to remove them when actually using the roof rack.

I intended these for TPU, but I did print a test piece in clear PETG as well. It works great and is a good option, but the XY size will need to be reduce a small percentage. If you want a rigid print and need help resizing, let me know!