Fridge Door Tray Nipple for E522B (Fischer & Paykel)

thingiverse

My fridge (a Fischer & Paykel E522B) refuses to hold its trays in all normal positions due to broken "nipples" that the trays sit in, a term I'll use for lack of better words. These replacements are attached to the door with M3x25mm bolts and nuts. Modeled on Shape (https://cad.onshape.com/documents/ee0bce8f0dc5fb7ed965b2c6/w/e40bd2d1fd9178afbd2a5811/e/c652dcdd64a2233d378fafff) STLs: Nipple_NoHole is a simple version, with no bolt hole or nut inset. Nipple_Small was my first version, intended to sit on the door foam. Nipple_Big is an improved version, meant to sit "over" a hole in the door's plastic exterior. These doors usually feature a thin layer of plastic over a body of foam insulation. The original nipples were molded into that plastic layer. When I got this fridge these nipples broke off, essentially leaving small rectangular holes in the plastic outer layer. The first version (Nipple_Small) sits inside those holes on the foam, and has small spikes at the back to prevent it from rotating when the bolt is tightened. However, tightening the bolt just squishes the foam. I still use this model for the lowest nipples on the door but it's not aesthetically pleasing (see the last photo). The second version (Nipple_Big) sits atop those holes hiding any damaged plastic. To account for this, I increased the size of the "lip" around the nipple as well as the spikes in the back. This is a much nicer approach. If I have issues with the bottom nipples (small version), I'll replace them with this one. Generally speaking, I use 20mm M3 bolts for the small version and 25mm M3 bolts for the big version. Most of the time I trim the bolt by a few mm so it doesn't stick out the end of the nipple. After positioning the nipple as desired, I drill a hole through the part of the door where the nipple attaches (entirely interior to the fridge chamber). The head of the bolt is toward the edge of the door, as seen in my photos. The likelihood of someone needing this very specific part for this particular appliance is quite low but maybe my approach and what I learned will be useful to someone someday.