Endcaps for screen in hatch
 

I'm experimenting with making an endcap for the square end of the shade thing. My spring is ok, the plastic is broken. Thus far, I've cast one from aluminum and am machining it to match. After anodizing, I'll reinstall the shade and not have to worry about it breaking again. Anyone need one?

Dave951M

I do! How much you want for one? I have been through two. And I can't find a third.

I'm confused about what you're refering to

I'm refering to the window-shade thing that covers the cargo area. It attaches to the back of the fold down portion of the rear seat. The common failure modes are, the spring that winds it up break, or one of the end caps on the bracket break. Mine broke on the driver's side. That's the one where the spring exerts most of its torque. Since my brother and I are experimenting with casting aluminum, we figured we would give it a shot. The first one looked ok, but we are refining the mold a bit. I thought of getting a used one, but it's plastic. I figured an aluminum one would be much more durable and could be anodized or polished to suit. I'll post the results later today.

Dave951M

I'd be interested for sure...let me know

Dave count me in. i need for 2 shades

Count me in as well, money is not the issue (just kiddin, but I will spend a reasonable amount).

Minor setback. Broke my only 1/8 center cut end mill last night and am getting a new one today. We tried sandcasting the aluminum and finishing with the mill. I think this was what started the end mill's early demise. The result was ok but we're going to make a steel mould that should give a much better initial finish so only very minor machining will need to be done ie. drilling the mounting holes. When we get finished, the part can be installed by drilling out the old pop rivets, painting or anodizing the new one and pop riveting it back on. We are also looking at reproducing the seat back release that seems to break very easily. That should look really good in natural aluminum against a black interior.

Dave951M

Are you making them for both sides?

Hi Dave well it sounds like cool Idea , but i have afew questions, first the end caps are different one side is just a pin that the shade rolls on and the other side has a long piece of metal (2 inches or so)that actually goes into the middle of the shade to hold the spring under tension, what I found is that sometimes the middle of the shade that the metal goes into will crack and then the metal pin that holds the spring will not hold anymore IE it will be stripped ..So I wanted to know what side are you planning on making the side with the lil pin or the side that does the tensioning?
Also for anyone that is planning on working on there shades I found that the only way to get the tensoining pin back into the shade is to take some 3/4 in extensions and put them together they will have to be longer than the shade as you will need to put them down the inside of the shade tube to press the long tensioning pin back into the middle of the shade spring tap gently with a hammer, then turn the tension cap in the correct direction to pre tension the spring B4 you put the tension side onto the shade carrier............
I used parts from another shade to repair the one in my car but they are both cracking again... so some stronger end caps might be in order...... any comments, Dave?? ............Stan

I am interested...I have 2 shades, and they both need end caps!...Cus

Ok, with new end mill in hand, we have an end cap and it works. We made the one opposite the one with the pin. The pin side (passenger side) on mine wasn't broken so I set that one aside for a while. We're making a mould from the first one to make a more refined one next. Since we have a mould now... why not make a few extras for those who need them? We are also going to experiment next with the seat back release knobs. I'll keep everyone posted, but at the moment, my brother is going to have to handle that project since I'm repairing my headers.

Dave951M