Thule Chariot CX trailer - narrow pushbar steel tube connector idea

thingiverse

We have acquired a Thule chariot for our little girl. I wasn't fond of the original pushbar; it's extremely wide, causing a lot of rattle while pedaling. It also makes the trailer rather large, and we have a small home. This design connects both tubes using an M5 bolt, ensuring that if the plastic fails, the bolt will still hold everything together, adding to safety. It should be noted that Thule doesn't allow modification to the trailer, and I'm in no way responsible for any modifications made; this is provided "as is." You'll need 19mm and 22.2mm tubing for this project, and I used 4130 for the build. For the nut holder/insert, I used a 19x0.9 size; if you use thicker tubing, you may require a different insert. Soft washers (nylon or so) should be used to avoid damaging anything, and don't overtighten - use locknuts instead. Be careful when drilling holes; my second hole was slightly off.