Kuat NV bike rack wheel tray end cap
The plastic caps on the ends of Kuat NV and Sherpa wheel trays crack in the cold and let water into the extrusion. This replacement cap is a rectangular plug with a 3 mm face plate, four 1.5 mm ribs that friction fit into the tray's hollow section with 0.2 mm interference, and a 5 mm hole for the original retaining screw. Dimensions come from the measured tray opening; print it face-down in ASA or PETG at 50 percent infill so it shrugs off road salt and UV.
Tray extrusions differ between Kuat, Thule T2 and Yakima HoldUp racks and even between generations, so a downloaded cap may be a millimetre off and fall out on the motorway. Measure your tray, tell SpeakCAD the opening size and screw position, preview the cap free in the browser, tweak the rib interference in the chat, then download the STL.
Model a rectangular end cap for a 60 x 28 mm hollow aluminium tray with a 3 mm face plate 64 x 32 mm, a 15 mm deep plug with four 1.5 mm friction ribs at 0.2 mm interference, a 5 mm screw hole and 2 mm rounded outer corners.