No

No

.2

20%

I printed at .2mm layer height, but then enabled automatic variable heights to get smooth hinge pin holes and a nice curve on the end where it rides against the spring plate.

Just 2 perimeters (default Prusa slicer) and 20% infill with honeycomb and this is a strong replacement that prints in just 51. minutes.

I used gray PETG for strength and to stop warping in hot summer sun. PLA seems risky for something that will be outdoors.

The leviton plates have a bronze colored hinge pin that you can slide out from the back by wedging something narrow at one end. Once it slides a bit, you can grab the other end with pliers and pull it out. The metal springs provide tension to hold the cover shut.

These are supposed to have a neoprene gasket to keep them “waterproof”. Since the existing covers are broken, mine have not been waterproof for years—if I needed good protection like that I would simply replace the whole cover plate with something new. Since I am really just trying to keep dust out and improve the aesthetics, a gasket isn’t really necessary, as this works without one, but if you have some self-adhesive weather stripping, that would work perfectly!

I cut a piece of quarter-inch neoprene foam from an old shipping container from something. At 40x35mm is fine to compress-fit into the inside and the quarter inch thickness lets the cover sit nice and flat/straight. Again, not really needed, but a nice touch.

I built this using Tinker CAD in about 40 minutes by measuring originals with calipers. No frills, just a simple, boxy design to sit flush with the hinge. Dimensions are mid-range for a couple different versions I have on the house and I think this will work on both.