Smart ForTwo 行李箱盖杆端盖

Smart ForTwo Luggage cover bar end caps

2024-04-16 01:28:03

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Summary

The luggage cover on the Smart ForTwo/ City Coupe (450) is supported by metal bars with rubber end caps. These end caps rot and fall to pieces after a few years, and whilst the genuine Smart replacement parts are still available, this is a perfect application for 3D printing.

The original caps come in two different sizes, one size for the lower bar and another size for the two upper bars. However the slots that retain the two upper bars are slightly different sizes and I noticed the original parts were tight in one slots and loose in the other so this project includes custom made sizes for each position that holds the bars tight enough not to rattle whilst still being easy enough to remove.

The three different end caps have a letter on the end to designate it's correct position:
L = Lower bar
F = Front upper bar (bar closest to the seat backs)
B = Back upper bar (bar closest to the tailgate).

These parts must be printed in a flexible filament as the inner holes are slightly undersized to create a good fit onto the 12mm metal bars, and the outer is slightly compressed when fitted into the mounting slots. I used a generic 95A TPU which works nicely and is easy to print with.

Print Settings

Printer brand:
Kingroon
Printer:
Kingroon KP3S
Rafts:
No
Supports:
No
Resolution:
0.2
Infill:
100%
Filament brand:
Sain-Smart
Filament color:
Black
Filament material:
TPU
Notes:
Print with closed end of cap on build surface, no raft or supports required. I found 220c nozzle temperatures and 50C bed temperature gave good adhesion without being difficult top remove, and printing at a slow 25mm/s gives a better finish though still acceptable at 50mm/s.