Golf 7 wagon roof rack adapter

thingiverse

Built this quick roof adapter for our family car's special rails to allow the skibox to sit as low as possible. I made a few tries before fastening it with a metal band below using a Simpson Strong-Tie Practilett-Lochband. When using a plastic base, it would eventually crack even if printed very thick with high infill percentages. This construction is not a perfect fit but allows the plastic to expand during temperature changes. I tested it down to -23c with PLA, and I would use ABS or ASA if used in summer. You'll need Thule "old style" square bars (22mm x 32mm) covered with a rubber sleeve. Also required are four M5 45mm bolts and four M5 nuts, preferably Nylock for extra security, although wing-nuts can be used for easier installation or removal. Some Simpson Strong-Tie Practilett-Lochband is necessary, which I used in 17 x 0.9 mm thickness with a 7mm hole diameter and three loops. I wrapped my metal band with heat-shrink to protect the aluminum roof rail. You can drill holes before installing bolts for easier assembly. Optionally, you can drill through the Thule bar and attach an M6x60mm bolt to secure it to the mount. However, due to the design's cutout in the mount, it is self-locking.