Replacement latch mechanism for Thule Cascade Cargo Box

Thule Cascade rooftop cargo boxes (and perhaps other varieties) are hard to fix when the lock assembly has been damaged or removed. Thule does not sell replacement parts for the locking assembly (the camlock).

This design is a non-locking solution that allows you to easily latch and unlatch the box using a 3/8" carriage bolt (16 threads/inch), some 1/4" hardware, nuts, and these 3D-printed parts.

All parts can be printed without supports. Knob is threaded and screws on to a 3/8"-16 bolt.

Instructions:

1. Drill two half-inch holes to the left and right of the original hole, to extend the range of the slide mechanism. Align holes with the rear sliding metal part.

2. Attach the 3/8" bolt so that it sticks out or the newly drilled holes -- use a nut to hold the bolt in place against the slider. I used a grinder to make the bolt fit better within the metal sliding mechanism.

3. Align the 3D-printed Slider Guide with the new bolt—drill 1/4" holes where you'll attach the Guide. Attach this to the cargo box using 1/4-20 bolts and nuts.

4. Screw on the knob and try it out.