Universal Cooler Lid Hinge, Two-Leaf Replacement, 70 or 100 mm

This is a two-leaf hinge to replace a broken lid hinge on an ice chest or cooler. Two identical flat leaves, each with a row of knuckles that interleave along one long edge, are joined by a 5 mm pin. Screw one leaf to the lid and the other to the body. The standard set fits a 70 mm hinge footprint, and the wide set is for large coolers.

Standard set: a leaf 70 x 30 mm with 6 knuckles and screw holes 50 mm apart, plus a 72 mm pin. Wide set: a leaf 100 mm long with 8 knuckles and holes 80 mm apart, plus a 102 mm pin. Print two leaves per set. Plate thickness is 4 mm, barrel outer diameter 10 mm, and each leaf has two countersunk holes for 4.5 mm screws (9 mm head). The pin hole is 5.3 mm, so you can use the printed pin, an M5 bolt with a nut, or a 5 mm steel rod.

To assemble, turn one leaf 180 degrees so its knuckles slot between the other leaf's, then push the pin through.

Print settings: ASA for sun exposure, PETG otherwise. 0.2 mm layers, 4 walls, 40% infill, no supports. Print each leaf flat on its plate with the countersinks facing up. A brim helps with the small curved overhang under the barrel.

This is a free design offered as-is, with no guarantee that it fits your cooler or carries your lid's weight, and it has not been tested on the original hardware. Check your hole pattern and loads first.

Don't have a printer? PartRevive prints this and ships it: https://jdinneen.github.io/partrevive/parts/cooler-lid-hinge/