With the OEM front to back rails being an awkward shape, anybody that wanted to install an awning had to either drill into the horizontal members or come up with some other contraption that didn’t seem too appealing. I designed and 3D printed these mounting blocks to affix my foxwing awning. They fit into what I think is a fairly standard track which uses M6 bolts spaced at 48mm on center. I lined the inside with 1/8” neoprene to not damage the rack and also provide additional traction. The blocks are printed to hold the angled plates that came with the awning. I plan on cutting down and keeping them for added strength, but they can be printed without the tabs and just use a regular spacer plate.

That's awesome! The neoprene looks very cleanly installed - kudos.

Keep me informed how this holds up to the stress and temp!

Will do. The stress is my biggest concern but the plate alleviates that by essentially turning it into a U bolt. We'll see how it deals with the cold...it's not supposed to get above freezing here for at least a week and a half...

What plastic did you use?

I am finishing up my nylon enclosure. I am excited to print stuff that can stand up to some abuse.

This was printed with PLA and 50% infill. I had to do a couple revisions because originally the blocks weren't pushed as far out and the rail made contact with the end caps of the rack. It's been sitting in 10* weather for the better part of a week and still holding pretty strong. I've got some buckles and nylon webbing on order that I'm going to fab up some straps to tighten the awning bag up though since it's a bit loose. Probably gonna print a piece to hold those straps in place as well. Getting the profile to properly match up the OEM rail was a bear though, went through a couple of iterations there.

any possibility that you would consider making one for the sport roof rack?

Sure - I've considered selling them but wasn't sure if there'd be much interest. I'm working on mounts for other items like cameras, lights, shovels, etc. also. From a quick google search it looks like the Sport edition has the same profile as the Limited?

I'd highly recommend reprinting out of something a little less biodegradable than PLA. It's not very UV stable. PETG is doable on most machines, and I think you'd be much happier with it long term.

My research was indicating that most of the UV degradation came from UVC rays which are more often reflected back by the ozone layer, however I do think that if I were to sell them I’d probably go the ABS route with an acetone bath to seal it since it’s a bit of a stronger. Thats for another discussion though.

EDIT: Looked into it a bit more, I was thinking PETG would be significantly more expensive, but with them being a similar price to ABS I think a solid route would be PETG as you mentioned and spray on a layer of UV protectant clear coat.

The sport has a different angle, and is round tubular. that said I am not familiar with the non-sport roof racks.

For the sport rack I've seen these used Modular Awning Mounts

Nice find. thank you.

What I would also like to try and find is a mount for my sand mats. i would prefer to mount to my extended Rola rack or my Gobi ladder.

open to and ideas, and i am pretty sure i may have to drill into them if i wound them externally mounted.

Yowza, those are pretty pricey. I guess milled aluminum can command the premium. I'll shoot you a PM and see what we're looking at.

Yeah, PETG can be a little more irritating to print, but it's worth it in the end usability of the finished print. Interlaminar strength is much higher.

What are you using for a bed surface? If you haven't tried PEI you're missing out!

I’m actually using transparency sheets like what teachers used to use in school for projectors. Print sticks to the bed super well (a lot of times too well if I’m printing a wide flat object lol), no glue and whatnot. I do want to find a better double sided tape though. I’m using carpet tape and it’s really pliable and a bit annoying to cut and work with. Then again it gives the bed a bit of a cushion so it might not be a bad thing.