Note : This print includes a TestRing section which can be printed to test the fit of the complete post cap.

I created this print to replace a post cap which was smashed to pieces (see photos) when a tree limp fell on my fence. Note the photos also show an “original” post cap (left side of the gate in the picture) along with the printed replacement cap.

This cap is for posts of nominal 1-7/8" diameter (nominally 47.6mm, but actually 49mm for my post). The cap is designed with a slightly elliptical opening; this allows for some automatic “diameter” adjustment to allow for small variations in post diameter, while still proving for a tight fit - the cap will effectively “squeeze” the post.

As noted, the fit can be tested in advance by printing the test ring piece. This also makes it possible to easily test scaled up sizes if needed.

Print Instructions

Print in PETG using the 3mf files provided, otherwise :

• 0.2mm layer height
• 3 perimeters
• 10% rectilinear infill
• Brim
• Variable layer height (adaptive)

CAD

The OnShape 3D CAD files for this are here :

https://cad.onshape.com/documents/b5b884dcdce39ddd8aa96820/w/fb73d8130fc2d4fddc2f47cb/e/1e2ff81803cbc444a1fb4fb7?renderMode=0&uiState=680185cb720c692eb6ad70ff