Replacement Rubber Foot for Subaru Cargo Cover

Overview

I needed to replace one of the little rubber feet that holds the front flap of the cargo cover in place in a 2009 Subaru Forester. I found this design and printed it but decided to make a few changes to make it easier to insert the replacement in the aluminum tube, as well as make the assembly hold together better before you insert it into the tube. 

As far as compatibility, I know that this design fits the 2009 Forester as well as the 2019-2020 Forester. Given that, it's probably a safe assumption that this will fit Foresters and Outbacks (which use the same cover iirc) from 2009 to present. This is probably closest to Subaru part number 65577AJ00BVH or 65577AG000JC. If for some reason this design isn't compatible with your vehicle and you want to modify it, Fusion 360 files are included. Knock yourself out :D

Hardware

You'll need 1 spring for this design. It needs to be <10mm diameter and you'll want it to be pretty stiff. Mine was 7.7mm diameter, 38mm long, and had wire diameter 0.78mm. I would say a spring that was slightly stiffer/longer would've been better. I think a 7-10mm diameter, 50mm long spring with wire dia 1+mm would be ideal.  If you still have the original spring from your cargo cover then just use that. 

Side note: you can get away with slightly shorter or weaker springs if you add spacers inside the sleeve to provide more spring compression. I've included a 10mm spacer in the files which can help bolster shorter/weaker springs.

Assembly

1. Insert spring (and spring spacer, if desired) into Sleeve.
2. Insert Bit into sleeve, compressing spring until square hole is visible through rectangular cutout. Ensure that Bit and Sleeve are positioned so that the top of Bit is aligned with the top of Sleeve.
3. Press Pin through the rectangular cutout in Sleeve and the square hole in Bit so that it protrudes out the left and right side of the assembly equally. Glue if necessary.
4. Slide Bit Cover onto Bit. Glue if necessary (strongly recommended)
5. Insert assembly into the metal rod on the vehicle cargo cover. Ensure that ridge and cutout on Sleeve are aligned with respective features in the metal rod.
6. Reinsert cargo cover into vehicle per manufacturer's instructions.
7. Enjoy life!

Printing Notes

Printing orientation is pretty self-explanatory; no supports required. Included some sample gcode using default Prusa profiles for reference. I did glue the Bit Cover to the Bit, just to keep it from falling off sometimes. 

Use a filament that can handle higher temps (PETG, ABS/ASA, Nylon) for the Bit, Pin, and Sleeve. PLA will soften in a hot car so avoid that; I used PETG. For the Bit Cover, use TPU or some other filament with flex/grip. This will help the foot stay in place when you put the cargo cover in. Black or grey will blend in with the original, but I only had orange so that's what I printed with.