Pannier-bottom protector QL2.1 with bracket for Thule Tour Rack
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Replacement bottom edge protector for Ortlieb QL2.1 pannier, adapted to Thule rack, secured to side frame with bracket.
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Ortlieb QL2.1 pannier bottom edge guard with bracket for Thule Tour Rack
Remix of Ortlieb pannier bottom edge guard by jmsaltzman, licensed under CC BY 4.0. Fit tested on an Ortlieb Sport-Roller Free 12.5 l with a Thule Tour Rack.
Parts
Part | Size (mm) | Volume |
|---|---|---|
Edge guard with hook-in staple | 257.6 × 52.9 × 33.0 | 38.8 cm³ |
Bracket | 65.2 × 70.0 × 25.2 | 29.8 cm³ |
The bracket has two holes, 26 mm apart, for M5 heat-set inserts (melted in with a soldering iron). The U-shape of the bracket sits over the bulge of the Thule frame and carries the load by form fit. Two M5 screws only dive into the existing holes of the frame and keep the bracket from sliding up when no pannier is mounted, they are not load-bearing. The Thule rack stays unmodified, so its warranty is not affected.
Why M5 and not M6: The holes in the Thule side frames vary from rack to rack, so M6 screws did not fit the existing holes on mine. M5 screws fit without modifying the frame. Check the fit on your own rack before melting in the inserts.
Print settings
Prusa Core One+, 0.4 mm HF Obsidian nozzle, PrusaSlicer 3.x beta, profile 0.20mm STRUCTURAL, generic PETG (250 °C nozzle, 85 °C bed), textured Satin sheet. PCTG should work as well.
Setting | Edge guard | Bracket |
|---|---|---|
Perimeters | 5 | 7 |
Infill | Gyroid 35 % | Gyroid 40 % |
Top / bottom layers | 5 / 5 | 5 / 5 |
Min. top / bottom shell | 1.0 mm | 1.0 mm |
Support | Organic, build plate only, threshold 40°, contact distance 0.2 mm | same |
Brim | outer only, 7 mm | outer only, 7 mm |
Orientation
Bracket: flat on its base plate.
Edge guard: tilted about 32° around its long axis and rotated 45° in the bed plane. It is longer than the bed is wide (250 mm), so it has to lie diagonally. This puts the staple legs flat on the bed, so bending stress runs along the layers.
Strength
Calculated, not measured: with an assumed hook force of 150 N (300 N exceptional) the bending stress in the staple and the bracket hook is about 10 to 12 MPa, roughly a quarter of the in-layer strength of PETG.
These parts have not been load-tested yet. The U-shaped legs of the bracket and the bulge of the Thule frame are not checked. Use at your own risk and inspect regularly.
Files
STL and 3MF (print-ready, PrusaSlicer 3.x beta), STEP as source.