B5 Avant Cargo Cover Repair

thingiverse

These are repair pieces I designed to fix a friend's damaged cargo cover on his Audi A4 Avant (B5). I'm not sure how common this exact failure is, but I figured I'd share it in case it helps someone from throwing out their cover and having to shell out for a replacement. There are other repair pieces for Audi/VW cargo covers that are used on wagon models like VW Jetta wagons and an A6 Avant. However, the repair parts are specific to those covers since the designs are different. The end result of these repairs is the same: allowing the shade to retract again. Typically, a plastic piece inside holds spring tension on the shade, which gets brittle over time and breaks, causing the shade not to retract inside the cover or stay taut when pulled over the rear trunk/cargo area. On this cargo cover, the plastic broke outside the end cap where the counterbore for the screw is. Due to where it broke and how the end cap goes together, it's very difficult to repair with glue alone. The plastic is extremely thin in this area. The screw threads into a plastic "plug" that is inserted into a metal rod running along the entire length of the cover. This rod stays stationary, held in place on one end in the same manner, and what the fabric and another tube rotate around to provide spring tension. I don't have many pictures of the cover disassembled, but if you're reading this, you likely know how it goes together. However, there's an Audizine thread that provides some detail on how to take it apart and put back together, although it's specific to an Audi A6 Avant. The files I've uploaded are a replacement screw anchor/plug for the main metal rod and the repair part glued to the outside of the end cap. The screw anchor was quick to design, and I figured it was a good idea to print one in case it gets lost or stripped out. The repair piece has a flange that's glued to the outside of the end cap. The taper and outside diameter of the cylindrical portion are critical since they need to fit inside the locking tab piece holding the cover into the cargo area trim panels. You may be required to scale the part in your slicer to get a good fit. The counterbore for the screw was designed at the same height so that thread engagement into the plastic anchor is the same. The flange thickness was made thick enough to provide strength while allowing the cargo cover to still fit between the trim panels. You may need to cut out some of the counterbore with a knife depending on how much of an elephant's foot you have on the first layer of the print so that the screw fits. Instructions: 1. Print parts. 2. The end cap may require drilling with a 1/2" bit or be filed to open up the hole where it broke, ensuring a snug fit around the repair part. 3. Sand the mating surfaces of the repair part and the end cap to improve adhesion for the epoxy, avoiding krazy glue or similar. 4. After applying the epoxy, make sure the repair part is aligned with the cutout for the locking tab. 5. Allow the epoxy to cure according to the manufacturer's instructions. 6. Reassemble the cargo cover (refer to the Audizine thread for instructions). 7. Install and enjoy your now functional cover!