Chevy Bolt Roof Rack Tower

V2 Edit

• Changed the holes to slots to allow for a bit of positional adjustment.
• Widened the allowance for the rivnut extrusions a bit for better fit
• Added a slope to the mount sits on the aluminum bar instead of floating above it
• Added 2mm more depth to the area which the bolts go through for better support

Uploaded the models in 3MF format now; which now also include objects around the holes so you can set those as modifiers to have more perimeters. This ensures that the area you are clamping down with the bolts can be solid plastic instead of crushable infill. You can see how this looks in the PrusaSlicer photo in which one support has the perimeters increased.

V1:

A slight remodel/remix of the "EMT Roof Rack Tower"; I ended up widening the pole support to use 1" (ID) electrical conduit, removed the bevel for a better print experience, added indents for the rivnut edge, and smooth a few sharp edges.

I printed this in PETG (tried NylonG, but without a heated chamber, the warping wrecked the parts) with a 0.8mm nozzle to speed things up.

If you have a large enough print bed, you can print all 4 at once (I only did 3 in the picture as the first was done solo to verify).

Print Settings

Printer Brand:

Prusa

Printer:

Rafts:

No

Supports:

Filament: PETG