Aerodynamic end cap for square Thule bars
Description
On an electric car, Thule square bars have a noticeable impact on range. Replacing them with aeroblade is cost prohibitive. The solution ? 3d print them ! This thing is an attempt to increase the range of my electric car, with Thule Bars installed. The chosen profile and turbulator is inspired from a Hang glider control bar section. The base is angled so that they can fit flush with feets. The provided file is the left side. Don't forget to mirror them before printing the right side ! To install, simply remove actual end cap, and slide the printed one. A heat gun is helpful to soften the cap, once hot, it can be inserted more easily, and remains in place. I also 3d printed middle sections, but it just takes too much plastic. I have already noticed that the noise is down but cannot confirm yet that the Kilowatt per kilometer went down. Last summer, I calculated a drop of 7% in range just by adding the bars on roof. Printed on a ANET A8, in PETG and a 0.8mm nozzle @ 240 C. They seems sturdy, they already survived transportation of a Chrismas tree :)
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